Hatz Repair Manual PDF

Workshop manual
2-4L30.
H2-3L30.
2-4L31.
2-4L40.
2-4L41.
2-4M31.
2-4M40.
2-4M41.
438 402 00 - 1.97 - 0.4 Printed in Germany
Bestellu
Order fo
Comma
Pedido d
Ordine p
1 Bestelle
2 TYP
MOTOR
MIN -1
3 Ersatzteilli
4 St ck / Qt
5 Versanda
Post / Sur
Express /
6 Versanda
Bestellun
- die n ch
- your ne
- votre st
- al servic
- al piø vi
Contents
Introduction
1. General 2. Additional equipment
Sealants and adhesives A 01.00 Fuel
Illustrations of engine A 01.40 Delivery pump with hand pump
Type plate data A 03.00 Exhaust
Technical data A 03.12 Detaching and attaching
Lubricating oil circuit enclosure for silencer (muffler)
Special tools and A 04.00 Mechanical starting
Workshop equipment A 04.10 Crank handle
A 04.20 Automatic decompressor
A 04.70 Engine rotating device
A 04.80 Start release
A 05.00 Electric starting
A 05.40 Alternator
A 07.00 Lubricating oil
A 07.10 Lubricating oil cooler,
air cooling
A 07.11 Lubricating oil cooler,
water cooling
A 11.00 Automatic mechanisms
A 11.70 Temperature-controlled
starting fuel volume regulator
A 15.00 Housing
A 15.20 Adapter housing
A 30.00 Liquid cooling
A 30.20 Water pump
A 30.40 Thermostat
L / M . . 01.97
Contents
3. Basic engine equipment

M 01.00 Crankshaft M 14.50 Adjusting work with
M 01.10 Balancing weights 2L / 3L injection pump PFR 1K 80
M 01.20 Balancing weights, 4L M 14.60 Adjusting work with injection
M 01.30 Cleaning crankcase, pump PFR 1K 90
installing injector nozzles M 17.00 Flywheel
M 02.00 Crankshaft M 20.00 Engine shutdown device,
M 04.00 Camshaft belt tensioner
M 04.10 Camshaft for valve timing M 22.00 Air cleaner
M 04.20 Camshaft for injection pump M 31.00 Crankcase breather
M 04.30 Governor and injection timer M 32.00 Speed control
M 05.00 Conrod M 32.10 with injection pump
M 06.00 Piston and cylinder PFR 1K 80
M 06.10 Air-cooled engines M 32.20 with injection pump
M 06.20 Water-cooled engines PFR 1K 90
M 07.00 Cylinder head M 35.00 Enclosure
M 07.10 Air-cooled engines
M 07.20 Cylinder head repairs
(air-cooled engines)
M 07.30 Water-cooled engines
M 07.40 Cylinder head repairs
(water-cooled engines) 4. Tables
M 10.00 Oil pump
Tightening torques
M 11.00 Timing case cover
Repair data
M 12.00 Extra fuel device
Fuel injection equipment and
M 12.10 with injection pump
adjusting values
PFR 1K 80
Governors
Lubricating oil contents and dipstick
PFR 1K 90
Key to circuit diagrams
HATZ wiring identification
PFR 1K 90
Circuit diagrams
from serial No. L/M31.12,
Trouble-shooting table for the
M40.16, 2L40.19, 3-4L40.18
electrical system
and L/M41
M 13.00 Fan
M 14.00 Fuel injection equipment
M 14.00 Injection pump, functional test
PFR 1K 80
PFR 1K 90
M 14.30 Injector
M 14.40 Injector nozzle
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 specifi-
cally in this manual.
Please refer to the operating manual for details of routine maintenance work, operating
fluids and materials, troubleshooting etc.
Use only genuine HATZ spare parts in repair work.
Comply also with generally or locally valid legislation and with the instructions issued by
trade associations or accident insurers.
The details provided here may differ if special equipment is installed. Please appreciate
that neither the workshop manual nor the spare parts list can take all such deviations
into account. If problems occur, please contact the nearest HATZ service point.
L / M . . 01.97
1. General
L / M . . 01.97 1
Bestellu
Order fo
Comma
Pedido d
Ordine p
1 Bestelle
2 TYP
MOTOR
MIN -1
3 Ersatzteilli
4 St ck / Qt
5 Versanda
Post / Sur
Express /
6 Versanda
Bestellun
- die n ch
- your ne
- votre st
- al servic
- al piø vi
Sealants and adhesives
Use of sealants and adhesives:
Code letters in the text and drawigs refer to the products stated below.
The same details appear in our spare part lists.
A = 502 230 01 Loctite Activator 500 ml

B = 502 231 00 Loctite 573 50 ml
C = 502 232 00 Loctite 601 50 ml
D = 502 233 00 Loctite 221 50 ml
E = 502 234 00 Loctite 648 10 ml
F = 502 238 00 Technicoll 8058 750 g
+ 502 239 00 Technicoll 8367 750 g
G = 502 565 01 Loctite IS 407 20 g
H = 502 825 01 Silicon 30 ml
J = 502 830 02 High-temp. paste 1000 g
K = 503 426 00 High-temp. paste 100 g
L = 502 566 00 Silicon 100 g
1 L / M . . 01.97
Engine illustrations
26 7 1 2 3 22 6 21
25 23 13 5 24
1680/18 1680/4
Service and flywheel side Starter and flywheel side

Engines: 2 - 4 L . . S / Z
1 Lub.-oil filling and dipstick
2 Speed control lever
9 8
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
11 27 10 4 12 24 Starter
25 Fuel feed line
1681/4 26 Fuel return line
Governor and exhaust side 27 Belt pulley with 1/2" internal square
for cranking engine
L / M . . 01.97 1
9
15 22 24 14 1
25 23 7 6 4 5 2 26 27 20 23 17
1583/12
1583/6
Service and flywheel side Service and governor side

Encapsulated design
1 Lub.-oil filling and dipstick
2 Speed control lever
4 Oil drain plug
17 16 14
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
28 11 10 23 Engine brackets
1583/3
Outgoing air and flywheel side 25 Engine flange
26 Side panel
27 Cover, service side
28 Cover, outgoing air side
1 L / M . . 01.97
1627 / 12 1627 / 6
Service and governor side Starter and flywheel side
Engine: 2 ... 4 M 31, Engine: 2 ... 4 M 31,

2 ... 4 M 40, 2 ... 4 M 40,
2 ... 4 M 41 2 ... 4 M 41
1 Lub.-oil filling and dipstick 1 Cylinder head cover
2 Side panel 2 Fuel pressure pipe
3 Rain protection cap 3 Cover for air filter(s)
4 Cooling fan drive belt 4 Eye hook for transport, max. load 500 kg
5 Cooling fan with built-in alternator 5 Injector
6 Governor housing 6 Fuel return line
7 Hydraulic belt tensioner 7 Fuel feed line
8 Stop device 8 Wiring harness duct
9 Belt pulley with 1/2" internal square 9 Flywheel
for cranking engine 10 Engine flange
10 Oil drain plug 11 Starter
11 Speed control lever 12 Type plate
12 Lub.-oil filter 13 Exhaust silencer
13 Oil drain plug (oil sump)
14 Cooling air duct for lub.-oil cooler
L / M . . 01.97 1
Service side Governor and exhaust side

Motor: H 2 L 30, Motor: H 2 L 30,
H 3 L 30 H 3 L 30
1 Fuel line (feed pump - filter) 1 Cooling water inlet
2 Fuel line (filter - injection pumps) 2 Rain protection cap
3 Hose connection 3 Air filter
(Maintenance indicator for air filter) 4 Cylinder head cover
4 Primer pump 5 Fuel pressure pipe
5 Fuel feed line 6 Temperature switch
(Fuel tank - fuel feed pump) 7 Cooling water outlet
6 Lub.-oil filling and dipstick 8 Exhaust manifold
7 Speed control lever 9 Starter
8 Solenoid, engine stop 10 Type plate
9 V-belt 11 Centrifugal pump
10 Voltage regulator 12 Belt-adjustment link
11 Oil drain plug, governor side 13 Alternator
12 Lub.-oil filter IMPORTANT !
13 Oil drain plug, lateral The standard transport suspension enables
14 Fuel pre-filter safe transportation of the engine including
15 Oil pressure switch supplementary equipments, and is designed for
16 Fuel feed pump (Bosch) a maximum load of 500 kg (1100 lbs).
It is neither suitable nor approved to lift
complete units.
1 L / M . . 01.97
Type plate data
Engine No.
Type No.. 064 10 81 031814
Engine serial No.:
The serial no. begins
with 10 and changes
Type designation continously (11, 12)
if any major changes
e.g. 2 L 40 C are carried out.
Engine type
Variant Year of production
Fabrication No. (continous)
Costumer spec. list No. 1)

Customer specification
MOTORENFABRIK HATZ GMBH
+CO KG
D-94099 RUHSTORF
TYP KENNZ.
MOTOR / FABRIK NO. ABE / AUSF. Output in kW 2)
MIN -1 NH PV CM 3
Execution code 2)
MADE IN GERMANY
Displacement in cm 3
Engine speed
Adjustment instruction 1)
e.g. 3000 / 60 Special adjustm. regarding
engine speed, power output etc.
Nominal speed
Speed increased under
no-load condition Injection pump delivery lift in mm
to obtain the required engine output.
max no-load speed Governor rod travel for adjusting the
3000 + 60 = 3060 min -1 correct fuel quantity in 1/100 mm
1) If required
2) In special cases only; e.g. engines acc. to Federal Authority for Automobilism
L / M . . 01.97 1
Technical data L 30
Type 2L30 H2L30 3L30 H3L30 4L30

Operating cycle 4-stroke
Combustion system Direct injection
Number of cylinders 2 3 4
Bore / stroke mm 95 / 100
Displacement cm3 1416 2124 2832
Compression ratio 18:1
Firing order.
cyl.1:timing end 2-1 1-3-2 1-3-4-2
Direction of rotation anti-clockwise (looking at flywheel)
Cooling air requirement at
25 - 35 - 45
n = 3000 rpm m3/min
Combustion air require-
ment at
n = 3000 rpm m3/min 2.1 3.2 4.2
Net weight approx. kg
L 30 S 223 222 255 271 291
L 30 Z 228 228 262 279 306
L 30 C / K 276 - 331 - 396/386
Lubricating oil pressure at n = 800 rpm1 min.: 0.9 bar
Lubricating oil consumption max.: 1 % of fuel consumption, at full load
Starter motor 12 V. 2.7 kW or 24 V. 4.0 kW
Alternator 14 V. 50 A or 28 V. 40 A*
Battery 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah
Max. continuous inclination with and without with without only with
towards oil sump oil sump oil sump
Control side 30° 30° 25° 25°

Flywheel side 30° 22° 25° 18°
Air outlet/starter side 30° 30° 30° 30°
Timing end 30° 25° 25° 15°
* At H 2 L 30 and H 3 L 30: 14 V/ 33 A or 28 V/ 27 A
1 L / M . . 01.97
Technical data L 31. M 31. L 40. M 40
2 L 31 2 L 40 3 L 31 3 L 40 4 L 31 4 L 40
Type
2 M 31 2 M 40 3 M 31 3 M 40 4 M 31 4 M 40
Bore / stroke mm 102/90 102/105 102/90 102/105 102/90 102/105
Displacement cm3 1470 1716 2205 2574 2940 3432
Compression ratio 18:1
Firing order.
cyl.1:timing end 2-1 1-3-2 1-3-4-2
25 29 35 39 46 49
n = 3000 rpm m3/min
ment at
n = 3000 rpm m3/min 2.1 2.6 3.2 3.9 4.2 5.2
L 31 S. L 40 S. M 40 223 255 291
L 31 Z. L 40 Z. M 40 Z 228 262 306
L 31 C / K. L 40 C / K 276 331 396/386
Lubricating oil pressure at n = 800 rpm min.: 0.9 bar
Alternator 14 V. 50 A or 28 V. 40 A
Control side 30° 30° 25° 25°

Timing end 30° 25° 25° 15°
L / M . . 01.97 1
Technical data L 41, M 41
2 L 41 3 L 41 4 L 41
Type
2 M 41 3 M 41 4 M 41
Bore / stroke mm 102/105 102/105 102/105
Displacement cm3 1716 2574 3432
Compression ratio 18.7:1
Firing order.
cyl.1:timing end 2-1 1-3-2 1-3-4-2
29 39 49
n = 3000 rpm m3/min
ment at
n = 3000 rpm m3/min 1.9 2.9 3.9
M 41 S 223 255 291
M 41 Z 228 262 306
L 41 C / K 276 331 396/386
Lubricating oil pressure at n = 800 rpm min.: 0.9 bar
Alternator 14 V. 50 A or 28 V. 40 A
Control side 30° 30° 25° 25°

Timing end 30° 25° 25° 15°
1 L / M . . 01.97
Lubricating oil circuit
1
2
3
5
17
16 6
10
13
12
15
11 10 9 8 7
14
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
1 Rockers 10 Plug
2 Pushrods – on engines without oil cooler
3 Pushrod tubes 11 Threaded rod
4 Hydr. starting charge device or oil servo – on engines with oil cooler
5 Crankshaft 12 Oil suction strainer
6 Main bearings 13 Balancing shaft(s)
7 Hydraulic belt tensioner 14 Lub. oil filter with bypass valve
8 Lubricating oil pump 15 Oil cooler
9 Sump 16 Oil pressure switch
17 Oil pressure relief valve
L / M . . 01.97 1
Special tools and workshop equipment
Series L / M engines
No. Ident-No. Item Code

1 669 350 00 Pressing-in drift ∅ 9 mm for valve guides 03.1.1
2 612 110 00 Reamer 9 H 6 for valve guide 03.1.2
3 668 383 00 Clamp for fuel line 01.1.2
4 626 753 91 Impact extractor with accessories 03.1.1
5 630 094 00 Test nozzle 400 bar 03.1.2
6 629 223 01 Valve lifting tool 03.1.2
7 625 739 00 Pressing-in drift for valve stem seal 03.2.1
8 612 092 00 6 mm intl. hex. insert with centering pin 03.1.2
9 665 418 00 Driver sleeve for camshaft bearings 05.2.1
10 665 030 91 Overflow device for injection pump 05.1.1
11 612 087 00 Dial gauge – 1/100 mm 05.1.2
12 634 142 00 Honing tool 03.1.2
13 620 926 01 Oil pressure gauge 0 - 6 bar with flexible tube 03.1.1
14 624 838 91 Revolution counter for fuel pressure pipe 03.1.2
15 625 383 02 Digital multimeter 03.1.2
16 612 090 01 Piston ring pliers 03.1.2
17 626 383 00 Piston ring clamping tool ∅ 70 - 100 mm 03.1.2
18 624 845 01 Crimping pliers up to 6 mm2 03.2.2
19 633 178 00 Relay test box 06.2.1
20 631 191 00 Puller for belt tensioner bushings 06.1.2
21 631 203 00 Installation drift for belt tensioner bushings 06.1.2
22 632 913 00 High-pressure pump cpl. 05.1.1
1 L / M . . 01.97
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18
Testbox
ktions- und
Relais-Fun
87a 50
15 87
86
Injection - pump
– +
timing set
D
E C
B
A
19 20 21 22
L / M . . 01.97 1
Series L / M engines
No. Ident-No. Item Code

23 624 340 01 Marking device for radial position of injection pump 05.1.1
24 624 346 01 Gauge for measuring governor rod travel 05.1.1
25 624 347 00 Gauge for adjusting start of fuel injection 05.1.1
26 624 348 01 Calibrating device for tool - 25 - 05.1.1
27 624 349 00 Locating pin for governor rod 05.1.1
28 624 350 00 Fuel injection volume adjusting tool 05.1.1
29 606 000 00 Wrench for extra fuel device adjustment 05.1.1
(mechanical system only)
30 618 140 01 Multipurpose puller for use with tool - 31 - 03.1.1
31 618 418 00 Forcing-off screw for tool - 30 - 03.1.1
32 610 390 00 Forcing-off screw for centrifugal clutch 03.1.1
33 620 300 00 Forcing-off screw for centrifugal belt pulley 03.1.1
34 624 393 00 Assembly sleeve 05.1.1
35 621 056 00 M 10 x 1 guide pin for conrod 03.1.1
36 626 211 00 M 11 x 1 guide pin for conrod 03.1.1
37 604 628 00 Test pressure gauge for fuel injection system 03.1.1
38 620 307 01 Strap wrench 01.1.2
39 620 638 01 Locking device for tensioning roller 02.1.1
40 619 746 00 Holder for injection timer assembly 05.1.1
41 630 439 00 Gauge for oil spray nozzles 05.2.1
42 619 852 02 Air guide plate for 2 L / M 5Q.1.1
45 624 863 02 Elevating table, mobile 03.2.1
46 624 864 01 Adapter elements for - 45 - 03.2.1
Explanation of classification:
Example: 03. 1. 2
Manufacturer: 1 . . . Only available from HATZ
2 . . . Same item (or equivalent in function)
available commercialy
Necessity: 1 . . . Absolutely essential
2 . . . Useful or convenient
Type of
repair 01. . . Maintenance
02. . . Emergency repair
03. . . Repair in upper and external areas
05. . . Repair in area of driving gear mechanism
5Q. . . General overhaul
(including all the necessary tests)
06. . . Component repairs
1 L / M . . 01.97
23 24 25 26 27
28 29 30 31 32 / 33 34
35 / 36 37 38 39
46
40
42
43
41 44
45
L / M . . 01/97 1
2. Additional equipment
L / M . . 01.97 2
Bestellu
Order fo
Comma
Pedido d
Ordine p
1 Bestelle
2 TYP
MOTOR
MIN -1
3 Ersatzteilli
4 St ck / Qt
5 Versanda
Post / Sur
Express /
6 Versanda
Bestellun
- die n ch
- your ne
- votre st
- al servic
- al piø vi
A 01.00 Fuel
A 01.40 Fuel delivery pump
-3-
General:
- When installing the fuel delivery pump,
2
make sure that the delivery and suction li-
nes are connected correctly.
3
4 12
Dismantling: 5 6
- Disconnect fuel feed line with clamp - 3 -.
- Separate the fuel lines from the delivery
pump.
1
- Unscrew and remove nuts with spring was- 7
hers, and take off fuel delivery pump with 8
O-ring.
9
- Dismantle fuel delivery pump 1 in the nu- 10
merical order of parts illustrated (Fig. 182).
11
Note:
Since September 1992 fuel strainer 12 has
been replaced by O-ring 5.
Because of this, an input-side fuel filter must
always be used.
This input-side filter is supplied as a spare 182
part with the fuel delivery pump and also
with the repair kit for the fuel delivery pump.
Assembling:
- Assemble by following the instructions in
the reverse order as appropriate.
L / M . . 01.97
2
A 03.00 Exhaust system
A 03.12 Removing and installing the silencer (muffler)
enclosure(L 30, L 31, L 40, C/K)
–
3
Preparatory work:
- Remove the hood from the enclosure and 4

air outlet duct; see M 35.00.
Detaching:
- Take out hex bolts (184/1) and detach the
connecting stub pipe with exhaust pipe 2 1
(184/2). L3 / 228
On more recent versions, the exhaust pipe 184
is secured with a clip.
- Take out the machine screws (184/3) and
remove the connecting cover (184/4).
- Unscrew and remove the hex bolts (185/1).

1
L3 / 229
185
- Remove the machine screws (186/1) and

bolts (186/2).
2
L3 / 230
186
L / M . . 01.97
2
- Lift off the capsule with exhaust silencer
(muffler); see Fig. 187.
Note:
In some cases a spacing plate is installed
between the silencer enclosure and the air
duct housing.
- On the 2 - 3 L 40 from date of manufacture

5.85 on, 4 L 40 from 1.86 on and L 31, the
connecting stub pipe (189/1), sealing was-
her (189/2) and plate (189/3) are deleted.
L3 / 231
Five sealing washers are installed be-
tween the silencer and the exhaust 187
manifold.
- Pull the upper and lower sections of the en-

closure apart and lift out the silencer; see
Fig. 188.
Check the parts:

- Examine the enclosure sections and the si-
lencer 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. L3 / 232
The silencer must be installed without trap- 188
ped stresses (a two-piece holder for the si-
lencer 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 was-
1 2 3
her radially. Next, place the sealing washer
on the silencer. Radial play must not exceed
0.1 mm. If necessary, renew the
L3 / 233
sealing washer.
189
L / M . . 01.97
2
A 04.00 Mechanical starting
A 04.10 Crank handle
Version A 04.10.1
Standard crank handle:
This handle can be replaced at any time by
one with kick-back damping if this becomes
necessary or is required by regulations.
Warning:
There is a risk of injury if the shaft of the
crank handle or its tubular handgrip are
worn.
Preparatory work: –
Dismantling: –
Checking / repairs:
- Visual inspection.
- Inspect shaft 1 and tubular handgrip 2 for 2
wear or breakage.
1
Note:
If the shaft of the crank handle is worn, al-
191
ways renew the complete handle.
The tubular handgrip can be renewed sepa-
rately if necessary.
L / M . . 01.97
2
A 04.10 Crank handle
Version A 04.10.2
Handle with kick-back damping:
The version for M .. engines is marked A on
its housing, and takes the place of the stand-
ard crank handle if required.
Warning: 4 7
There is a risk of injury if the shaft of the
crank handle or its tubular handgrip are
12 8
worn. 11
Preparatory work: –
3
Dismantling: 15 10
14 13
- Remove parts in the order 1 ... 3 as illustra-
A 16
ted. 15 2 1
9
- Remove machine screws 4. 6
- Take off cover 5 with great care, so that 5
leaf spring 11 cannot escape.

Risk of injury! 192
- Remove parts in the order 6 ... 10 as illu-
strated.
- Hold torsion spring 13 in position in order
to maintain its tension.
- Pull leaf spring 11 away from its locking
pin and out of the hook eye on torsion
spring 13.
- Relieve torsion spring tension with a scre-
wdriver blade.
Caution - risk of injury!
- Take off parts 12 and 13.
Housing 14 remains in position with the
other parts.
L / M . . 01.97
2
Checking / repairs: Assembling:
- Visual inspection: - Install parts 13 and 12.
- Renew the complete starting handle if Use thread sealant D.
there is any damage in the area of cover - Make sure that the torsion spring is not
5 and/or housing 14. trapped; insert its longer end into the
- If necessary, renew pivot bushings 15 and groove on the corresponding locating pin.
shaft sealing ring 16. - Preload torsion spring 13 against the nor-
- Examine tubular handgrip 7 for wear mal spring pressure until the hook eye of
and/or other damage, particularly in the the spring engages behind the eye of
splined area. the through-hole.
- Install end plug 8, avoiding damage to the Caution - risk of injury!
splines. - Hold torsion spring 13 in position to pre-
The end plug must be installed to prevent vent spring pressure from being lost.
dirt and water from entering. - Push leaf spring 11 into the hook eye on
- Check condition of bushing and leaf spring torsion spring 13 and place on locking
at lever 9. pin.
- Check condition of leaf spring 11 and torsi- The rolled end of the leaf spring must
on spring 13. face toward the center of the housing.
Renew in case of doubt. - Attach lever 9.
- Check shaft 3 for wear and/or other forms - Push on tubular handgrip 7/8.
of damage. Check splines, lever and leaf springs for
- Renew O-rings and small parts. free movement.
- Apply app. 50 grams of lubricant K to
the inside of housing 14 and over all me-
chanical parts.
- Place a new gasket 6 on the housing.
- Carefully place cover 6 over tubular
handle 7.
- Insert machine screws 4 and tighten
them evenly in a crosswise pattern.
- Install shaft 3 in the order 3 ...1 as illu-
strated.
- Check operation of the complete crank
handle.
L / M . . 01.97
2
A 04.20 Automatic decompressor (M 31, M 40, M 41)
The automatic decompressor has the follo-

wing positions; Fig. 93:
0 = Operating position, with engine running

1 = Permanent decompression, automatic
device switched off
2 = Automatic decompressor switched on, kompr.
engine compression is built up auto- 0
matically after about 8 turns of the
handle.
Detaching: 1 2
- Unscrew cap nut (94/4) with sealing ring dekompr. dekompr.autom.
(94/5). L3 / 1
- Take off cover (94/20) with gasket (94/37). 93

On two-cylinder engines, shafts (94/14) and
(94/36) are connected together by coupling
sleeve (94/27) and 2 locking collets (94/23).
Camwheel (94/22) is then used at the se-
cond cylinder (flywheel side) instead of the
gearwheel.
Dismantling the automatic decompres-

sor:
- Unscrew and remove screw plug (94/1).
- Take out sealing ring (94/2), spring (94/6),
cap (94/7) and lifting pin with shims and
pressure pin (94/8, 9, 10).
- Unscrew threaded rod (94/19) and remove
spring (94/18) and pressure pin (94/17).
- Using a suitable split-pin driver, drive lock- L3 / 42
ing collet (94/16) about 3 mm into gear- 94
wheel (94/21).
- Turn the gearwheel through 180° and pull
the locking collet out with pliers.
- Take out shaft (94/14) and gearwheel.
L / M . . 01.97
2
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 instructi-
ons in the reverse order as appropriate.
Note:
- With the automatic decompressor in positi-
max. 46.1 mm
min. 45.5 mm
on ,,0“, note the correct position of the gear- b c
wheel (Fig. 95).
- Check that the lifting pin can move freely.
- When installing threaded rod (94/19),
make sure that pressure pin (94/17) is en-
gaged in the locating slot on shaft (94/14). B
Adjusting the automatic decompressor:

A
Adjustment is needed if: L3 / 43

a) the decompression effect is no longer
95
sufficient.
b) the engine does not reach its full com-
pression ratio (hissing noise when
engine is turned over and the decom-
pressor is not engaged).
c) cylinder head repairs are carried out.
Check dimension ,,B“:

- Use a suitable measuring tool to check di-
mension ,,B“; Fig. 95.
Note:
For this check, the rocker should rest lightly
on the valve stem but without opening the
valve (turn the engine over until the tappet is
resting on the base circle of the cam).
L / M . . 01.97
2
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 dri-
ve 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 re-
ached.
Note that when it is riveted into position,
the pressure pin is about 0.1 mm lower.
- Rivet the pressure pin into position, pres-
sing it firmly into the bore. The 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 po-
int.
Install the rocker finally, noting the end-
play; adjust valve clearance and check di-
mension (95/B) again.
Dimension Number of shim
Checking dimension ,,A“: ,,A“ in mm washers (Fig.94/9)
- Using a depth gauge, determine dimensi- 14,0 - 14,5 6
on “A” (Fig. 95); work out the number of 14,5 - 15,0 5
shim washers (94/9) needed according to 15,0 - 15,5 4
the table, and secure them with the pressu- 15,5 - 16,0 3
re pin (94/10) to the actuating pin (94/8). 16,0 - 16,5 2
- Check operation of the automatic decom- 16,5 - 17,0 1
pressor. 17,0 - 17,5 0
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.
L / M . . 01.97
2
A 04.70 Recoil starter
Preparatory work:
- Remove the silencer (muffler); see A 03.00.
- Remove the fan; see M 13.00.
Detaching the recoil starter: (Fig. 190)

- Take out machine screws 13 incl. spring
washer 5 and screws 12 with bushings 8
and washers 7, and remove them with bea-
ring bracket 11.
- Detach the hydraulic shutdown device;
see M 20.00.
- Remove the timing case cover;
see M 11.00.
- Take out machine screws 6 with spring
washers 5.
- Take off starting sleeve 4. L3 / 44
190
Checking parts:
- Check the starting sleeve and bearing
bracket for damage.
- Check shaft sealing ring 3 for damage and
renew if necessary.
Assemble in the opposite order of work as

described here.
L / M . . 01.97
2
A 04.80 Start release device (L /M 31/40/41)
–
1
Preparatory work:
- On C/K, take off hood at enclosure and
side panel; see M 35.00.
- On S/Z and M.., take off side panel and
cooling air duct for lubricating oil cooler.
2
Detaching and dismantling:
- Pull off fuel lines (113/1 and 2). Take out 1
start release device retaining screws and
remove the device.
113
- Take off spring (114/9), flexible gaiter (8)
and nut (6); take off cylinder (114/2) and
remove lock washer (114/5), lever (4) and
5 2
washer (7).
4
Checking parts: 6 7
- Place the cylinder (114/2) in a tank contai- 14
ning diesel oil. Apply an air pressure of 8
3
max. 1.5 bar to the hose line (114/1).
If air bubbles emerge from the cylinder, it 13
must be renewed.
- Check flexible gaiter for damage and re- 9
new if necessary.
Re-assembling the start release device: 114
Follow the dismantling instructions in the op-
posite order as appropriate; refer to Fig. 114.
Note:
When attaching to the engine monitoring
block, make sure that locking collet (114/13)
is pressed into the start position by lever Stop
(114/4), or else the start release action will
not take place; see also Fig. 116/1.
Before tightening machine screws (114/14),
move bracket (114/3) in the opposite directi-
on (see Fig. 116/2), to ensure that locking
collet (114/13) can move as far as possible
back to the ,,Stop“ position.
115
L / M . . 01.97
2
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 de-

vice 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“ positi-
on. 1
- Prime the fuel delivery pump with the lever

and at the same time check whether the pi-
rt
ston in cylinders (114/2) moves the lever
(114/4) correctly. Also check the cylinder
Sta
and hose unions for leaks. When the lever
is no longer actuated, spring (114/9) exerts
pressure on the piston, which should then
move back slowly (see Fig. 116).
2
116
Note:
If the fuel tank is located at a higher level
than the fuel delivery pump, the difference in
height between the fuel level in the tank and
the fuel delivery pump must not exceed 2
metres.
Failing this, the automatic engine protection
device will be put out of action and the engi-
ne cannot then be shut down electrically.
L / M . . 01.97
2
General instructions on the engine’s Checking operation of the alternator

electrical system: with voltage regulator (checking char-
- Never interchange the positive and negati- ging current):
ve terminals at the battery. - With the engine stopped and the starting-
- Do not disconnect the battery when the en- switch key at ,,0“, detach the B + line
gine is running. (leading to the battery) from the alterna-
- Avoid all risk of short-circuiting live cables tor and connect a DC ammeter with a
(for instance, never test whether a cable is scale reading of 0 .. 50 A between alter-
live by touching it to earth). nator terminal B + and the detached
- If the charge telltale light bulb blows, re- cable. Make sure that the loose cable
place it immediately.. cannot touch any metal parts of the engi-
- If any welding is done on the engine or the ne.
equipment to which it is fitted, attach the - Connect a DC voltmeter with a scale of
earth (ground) clip of the welding set as 0 . . 30 V to the battery’s positive and ne-
close to the weld area as possible, and gative posts.
disconnect the alternator from the electri- - Start the engine and note the meter rea-
cal circuit at connections ,,B +“ and ,,D -“. dings. Check the voltmeter display. With
- When cleaning the engine, avoid spraying the alternator in good working order and
water on the alternator or any other compo- electrical consumers in circuit, the am-
nents of the electrical system. meter should indicate a charging cur-
If this is unavoidable, first disconnect the rent. Its value depends on the battery’s
battery; before it is reconnected, dry all state of charge (if the battery is flat, the
components thoroughly with a compressed charging current is high, if the battery is
air jet. fully charged, the charging current is
- If a malfunction, for instance low battery low), but also on the consumpition of
charge, charge telltale light on etc, should electrical equipment actually in use and
be detected, always check the tightness of on alternator and therefore engine run-
cable connections and correct V-belt tensi- ning speed. If there are no consumers in
on before making any other operational circuit, a charging current should even
checks. be indicated at idle speed. If the alterna-
- For trouble-shooting in the event of a fault, tor voltage is too high, renew the voltage
see Section 4. regulator.
- When recharging the battery, disconnect
Test values System
the negative terminal.
- Avoid using electrical starting aids becau- 12 V 24 V
se of the risk of voltage peaks (these could Voltmeter reading 13.0-14.5 V 26-29 V
damage electronic components). Charging current at
13.5 V or 27 V
Battery voltage
- Engine speed
800 rpm (idle) approx. 25 A approx. 5 A
- Engine speed
1500 rpm 40-45 A 25-30 A
L / M . . 01.97
2
A 05.40 Alternator (air-cooled engines)
Preparatory work:
Encapsulated engines:
- Take off the hood, the air guide housing co-
ver and the impeller wheel. Unscrew and
remove the enclosure side panel; see M
35.00.
- Take off the Poly-V belt; see M 20.00.
Non-encapsulated engines:
- Unscrew and remove the V-belt guard if at-
tached.
- Take off the air guide plate.
- Take off the Poly-V belt; see M 20.00.
Removing:
- Detach the earth (ground) lead from the 193 (*HATZ internal cable marking)
battery.
- Disconnect the leads from the alternator
and mark them (Fig. 193).
- Unscrew the hex nuts and pull the rotor
with alternator out forwards.
- Unscrew the hex nut holding the rotor and
drive the alternator shaft through by stri-
king it with a plastic-faced hammer;
see Fig. 123.
Checking parts:
- Examine the fan and the belt pulley for evi-
dence of damage.
- If any grooves have broken away or are da-
maged, renew the fan with belt pulley.
Installing:
- Install the rotor and the alternator by follo-
wing the above removal instructions in the
reverse order as appropriate. 194
Note:
When connecting the cables to the alterna-
tor, make sure they are not accidentally in-
terchanged.
L / M . . 01.97
2
Notes on renewing the alternator:
When series production of Series L / M engi-

nes began, alternators made by SEV-MAR-
CHAL were used.
These alternators are no longer available as
spare parts, but can be replaced without dif-
ficulty 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 bre-
aking off the carbon brushes), the fan hou-
sing was also modified in the regulator area 195
when the PARIS-RHONE generator was in-
troduced. A cutout in the housing and deleti-
on of the retaining screw which previously
passed through at this point ensure that the
regulator switch can be renewed without ha-
ving to remove the alternator.
When replacing a MARCHAL alternator by a

VALEO type, you are recommended to per-
form the above modification; refer to Fig.
195. The time invested in this will easily be
made good by the time saved if the regula-
tor has to be replaced later.
When installing a VALEO voltage regulator,

make sure that the condenser supplied with
it is also installed (connection diagram is en-
closed).
L / M . . 01.97
2
A 07.10 Oil cooler (air-cooled engines)
Preparatory work:
- On engines with enclosure, take off the en-
closure hood and side panel; see M 35.00.
- On engines without enclosure, take off the
cooling air duct to the oil cooler.
1
Removing block-pattern oil cooler:

- Remove the oil line to the servo (only on ol-
der version of the engine).
- Take out machine screws (196/1) and de-
L3 / 189
tach the oil cooler.
196
Removing gilled-tube oil cooler:
- Take out machine screws (197/1) with
spring washers and detach oil cooler with
1 2 5
sealing rings (197/5).
- To dismantle the oil cooler: Pull the oil gui-
des (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. 3 4 2
L3 / 10
Checking parts: 197

- Make a visual check for cracks or damage
to the sealing faces.
- Clean the cooling surfaces.
Installing: 3
- Install the oil cooler by following the appro-
priate 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
L3 / 190
cooler will be unable to operate.
198
L / M . . 01.97
2
A 07.11 Oil cooler (water-cooled engines)
Preparatory work:
- Drain the coolant.
- Detach the coolant lines from the oil cooler.
Removing:
- Take off the oil filter (199/1).
- Unscrew and remove the threaded sleeve 5
(199/2).
- Take off the oil cooler (199/3) with spacing 4
ring (199/4) and O-ring seal (199/5). 3
Checking parts: 1 2
- Make a visual check for cracks or damage
to the sealing faces. 199
Installing:
- Install the oil cooler by following the remo-
val instructions in the opposite order as ap-
propriate.
Note:
- Install the oil cooler side with the sealing
ring towards spacing ring (199/4).
- Tighten threaded sleeve (199/2) to a
torque of 55 Nm.
L / M . . 01.97
2
A 11.00 Automatic devices
A 11.10 Engine shutdown solenoid (up to serial numbers

2 L 40.16, 3-4 L 40.15, M 40.12, L 30 and H.L 30)
Dismantling:
- Disconnect the solenoid and take off the
starting aid housing, taking care not to turn
the volume limiting eccentric.
- Take out machine screws (205/1) and re-
move solenoid (205/2). 1
- Pull eccentric shaft (205/3) towards the so- 10 2
lenoid and unscrew hex nut (205/4) with a
10 mm open-ended wrench.
- Pull out the eccentric shaft and remove 3
washer (205/5), lever (205/6), washer
(205/7) and spring (205/8).
Checking / repairs:
- Use a new O-ring seal (205/10). 8 6
- Check flexible gaiter for damage and re-
new if necessary. 7 5
4 9
Assembling: L3 / 199
- Proceed in the opposite order of work;
205
install end cap (205/9) with sealant C.
L / M . . 01.97
2
Adjusting engine shutdown and solenoid:
The solenoid does not need adjusting un-
less the adjusting nuts were turned or a new
solenoid has been installed.
- Press the solenoid fully in against the
spring loading. 2
- Insert solenoid adjusting gauge 621 471 00 1
(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: L3 / 200
If the adjusting gauge is not available, the
206
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. 1
- After adjusting, secure the adjusting nut
with locknut (207/2) and seal it with 2
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 pas-
±0.1
39.3
sage in the starting fuel supply device is
not blocked.
- Attach the gasket (note correct position of L3 / 201
oil hole) and press the solenoid by hand 207
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 re- 2
connect the solenoid. 4
Warning:
If the angle is positioned incorrectly when in-
stalled (at the right of the driver pin), the en-
gine will overspeed and could destroy itself
unless the solenoid is put out of action im-
3
1
mediately.
When the U-pattern driver pin was intro-
duced, incorrect positioning as described
above was ruled out.
L3 / 202
208
L / M . . 01.97
2
A 11.00 Automatic devices
A 11.70 Temperature-controlled starting fuel volume control
- 24 - 28 -
Adjusting:
- Screw in adjusting tool - 28 - and attach 4
measuring device - 24 -.
- Pull the speed control lever briefly to 3 2 1
,,Stop“ and then to the full-load position.
This places governor lever 1 against full-
load stop 2 of the starting fuel volume con-
trol.
- Zero the dial gauge.
- Screw thermo-element 4 carefully into the
bracket, until the dial gauge just begins to
move (the sickle-shaped lever is then
against the governor rod).
- Unscrew adjusting tool - 28 - at the 13 mm
170
hexagon until a clicking sound is clearly he-
ard, to indicate that the governor lever is
dropping into the increased-volume star-
ting position.
- Slowly turn thermo-element 4 back to a lo-
wer 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 engi-
ne components not yet in place.
Warning:
When adjusting, make sure that the thermo-
element is at a temperature of at least 20°C.
L / M . . 01.97
2
A 15.00 Housing
A 15.20 Adapter housing
Assembling:
- Drive locking collets (200/1) into the crank-
case.
- Attach the connecting housing, insert four 2 3
M 14 x 1.5 mm hex bolts (200/2) with 1
spring washer (200/3) and tighten to the 4
specified torque.
Note:
Apply sealant D to the bolt above inspection
hole (200/4), since this is a through-hole.
On engines without a adapter housing, the
equivalent screw plug should also be coated 5 6
with sealant D before inserting.
- Insert and tighten the two lower M 10 hex L3 / 143
bolts (200/5) with spring washers (200/6). 200
L / M . . 01.97
2
A 30.20 Water pump (H.L 30)
Preparatory work:
- Drain the coolant.
- Take off the alternator.
Dismantling:
(Fig. 201)
- Detach the coolant lines at the water pump. 2 1
- Unscrew hex bolts 1 with spring washers 2
and take off the water pump.
- Remove screws 3 with spring washers 4 7 6
and take off V-belt pulley 5.
- Take out screws 6 with copper washers 7
and remove pump element 8 with seal 9 10 4
from housing 10. 9
8
Checking parts: 5 3
- Check housing for evidence of damage.
201
Note:
If the following damage is detected, renew
complete pump element 8:
- Damaged pump impeller.
- Worn sealing ring in pump element
(water leaking from the hole in the pump
element).
- Bearing worn.
Assembling:
- Assemble by following the dismantling in-
structions in the reverse order as appro-
priate.Install pump element 8 with the wa-
ter drain hole facing down.
L / M . . 01.97
2
A 30.40 Thermostat (H.L 30)
Preparatory work:
- Drain the coolant (only needed if the upper
edge of the radiator is higher than the 1
thermostat).
2
- Detach the coolant line from thermostat co- 3
ver (202/3).
4
Dismantling:
- Take out retaining screws (202/1) with 6
spring washers (2).
5
- Lift off the thermostat cover (202/3).
Remove sealing ring (4) and pull out
thermostat (5).
Checking operation of thermostat insert: 202

Note: The temperatures stamped on the
thermostat insert indicate the start of its
opening movement and the maximum opera-
ting temperature.
- Suspend the thermostat insert and a ther-
mometer in the centre of a vessel filled
with water; see Fig. 203.
- Heat the water while stirring it.
- Check that the thermostat insert opens at
the temperature stamped on it.
- Remove the thermostat insert and check
that it closes correctly.
- Renew thermostat insert if defective.
Assembling: 203
- Clean the sealing faces on the cylinder
head, the thermostat cover and the seat of
the thermostat insert.
- Install the thermostat insert, using a new
sealing ring (the arrow stamped on it indi-
cates the direction of flow).
- Attach the thermostat cover again and
tighten its screws uniformly.
L / M . . 01.97
2
3. Basic engine equipment
L / M . . 01.97 3
M 01.00 Crankcase
M 01.10 Removing and installing balancing weights - 2L / 3L
Preparatory work:
- Remove the crankshaft, see M 02.00.
Dismantling:
- Unscrew and remove machine screws
(1/1) at driver (1/2).
Note:
On the 3 L, also unscrew and remove the
machine screws at the divided driver.
1
- Unscrew and remove the machine screws
(2/1) at the plate (2/2) and take off the pla-
te.
(On more recent version: secured with
stud bolts and nuts)
- Unscrew the plug from the thrust bushing
at the timing end of the engine and drive
the shaft out towards the flywheel end; see
Fig. 3.
- Drive out the thrust bushing (timing end).
- Take the balancing weights and driver out
of the lower part of the crankcase.
2
Checking / repairs:
- Check the shaft at its bearing points for
score-marks and correct dimensions; for
values, see Section 4.
- Check the needle roller bearings of the ba-
lancing weights for score-marks.
- Check the gearwheel with balancing
weight and the crankshaft-end gearwheel
for the balancing weights for signs of dama-
ge.
- Renew the O-ring seals at the thrust bus-
hings. 3
L / M . . 01.97
3
Assembling:
- Insert the thrust bushing (timing end) until
flush with the housing.
- Place the gearwheel with balancing weight
(flywheel end) and the balancing weight (ti-
ming end) in the lower part of the crankca-
se, insert the driver and screw hand-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 timing-
end thrust bushing.
- Tighten the machine screws for the driver

and use a depth gauge to measure end-
play at the balancing weights; see Fig. 5.
Note:
The timing-end thrust bushing (5/1) forms
part of the sealing face at the timing case co-
ver, and must therefore be flush with the
endface of the crankcase after driving in the
shaft.
Endplay can be adjusted by moving the
flywheel-end thrust bushing axially until the
value stated in Section 4 is obtained.
5
- Apply sealant D to the machine screws
(6/1) and attach the plate; also coat the
screw plug for the timing-end thrust bus-
hing with sealant D and screw it in.
Turn the balancing weights to ensure free
rotation.
Note:
When installing the oil sump and the crank-
case cover, apply sealant D to two M8 hex
bolts in each case at the timing and flywheel
ends, where a through-hole has been drilled.
L / M . . 01.97
3
M 01.00 Crankcase
M 01.20 Removing and installing balancing weights - 4 L
Preparatory work:
- Remove the crankshaft; see M 02.00.
- Take off the oil sump.
Dismantling:
- Unscrew the machine screws (7/1) at the
bearing journals (7/2) and pull them out.
Using two machine screws, loosen the bea-
ring journals and pull them out.
Mark the installed positions of the bearing
journals. 7
- Invert the lower part of the crankcase.
Note:
The joint line is a sealing face, and must not
be damaged. Place the crankcase on a woo-
den grid or frame; see Fig. 8.
- Unscrew splash plate (9/1) and take out ba-

lancing weights (9/2), then remove splash
plate (9/3).
L / M . . 01.97
3
- Check dimensions of bearing bushings
(10/1) and, if necessary, drive them out
with a suitable drift. First drive the end
caps out of the crankcase bores (10/2).
Checking / repairs:
- Check the bearing journals and bushings
for score-marks and incorrect dimensions;
for values, see Section 4.
- Check the balancing weight gearwheels
and the crankshaft-end gearwheel for the
balancing weights for damage.
10
Assembling:
- Blow through the oilways thoroughly with
compressed air.
Note:
Before installing the bearing bushings, make
sure that the oil hole is in the correct positi-
on; see Fig. 11.
11
- Coat the bearing bushings (12/1) with

sealant D and drive them into the housing
until flush, using a suitable drift; see Fig. 12.
- Coat the sealing faces of the end caps
(10/2) with sealant C and insert them again.
- Renew the end caps.
12
L / M . . 01.97
3
- Insert spacing rollers for the M8 screws in
the correct positions as shown in Fig. 13.
Note:
Insert the longer spacing rollers (13/1) at the
oil filter flange side.
13
- Insert splash plate as shown in Fig. 14, in-

sert the lower machine screws (14/1) and
tighten them. Screw the upper machine
screws (14/2) in only hand-tight.
14
- Insert the balancing weight with circle and

line markings as shown in Fig. 15, and
push in the bearing journal.
Note:
This balancing weight is driven directly from
the crankshaft.
15
L / M . . 01.97
3
- Insert the balancing weight with circle mark
(16/1) and push in the bearing journal.
Note:
When installing this balancing weight (16/1),
make sure that the circle mark on it is be-
tween the two line marks on balance weight
(16/2).
In this position, the circle mark on balancing
weight (16/2) must face the crankshaft.
16
- Take out the two machine screws at holes

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

upright again (joint line at the top).
17
- Insert the machine screws at the bearing
journals and tighten them to the specified
torque with a torque wrench; Fig. 18.
- Rotate the balancing weights and check
for free movement.
Note:
When attaching the oil sump, apply sealant
D to two M8 hex bolts in each case at the ti-
ming and flywheel ends, since these are in-
serted in through-holes.
Engines with an oil sump attached must not
have a ∅ 40 mm end cap installed in the lo-
wer part of the crankcase.
18
L / M . . 01.97
3
M 01.00 Crankcase
M 01.30. Cleaning the crankcase, installing the oil spray jets
- 41 -
Cleaning the crankcase

- Remove all screw plugs from the oilways
and, after cleaning the crankcase by im-
mersion in a cleaning bath or with high-
pressure cleaning equipment, blow it dry
with compressed air; flush out all oilways
particularly thoroughly and blow through
them, so that no particles of dirt or swarf re-
main.
- After this, insert all screw plugs again and
check that the aluminium or sheet-metal
plugs for the oilways are firmly seated. In
case of doubt, renew them; apply sealant
171
E to all plugs before inserting. To ensure
firm location, secure the aluminium plugs
with light punch-marks at the edge of the
hole in the housing.
Oil spray jets

- First check for firm location and accurate
spray direction; if necessary, re-align the
spray jet with light hammer-blows or bend
it carefully by hand until the correct positi-
on is reached. Check this with the gauge
- 41 - or work from the drawing shown here
(Fig. 171).
If oil spray jets have broken off or are loose,
new ones must be inserted. Proceed as fol-
lows:
- Remove pieces of the old jet from the drill-
way (with a suitable drift or similar tool); de-
grease the entire area thoroughly; insert
the new spray jet and drive it in initially
app. 6 - 8 mm farther than its final position.
Strike the projecting end lightly with a ham-
mer to bend it slightly and ensure a firm
seating in the bore (Fig. 172). 172
L / M . . 01.97
3
- Apply sealant E to the projecting end and
move the spray jet to its final position. Do
not dent the jet inlet bore; drive it in until
the end of the tube is flush with the oil
groove in the bearing seat (Fig. 173).
- Check the position of the jet outlet again,
and adjust if necessary.
- Apply sealant E again where the spray jet
passes through opposite the bearing seat;
the capillary action of the sealant will en-
sure that the tube is fully coated and can-
not shake loose in its seat.
Note:
On Series L 41 and M 41 engines, an oil
spray jet is also installed for cylinder 1.
173
L / M . . 01.97
3
M 02.00 Crankshaft
-8-
Preparatory work:
- Take off enclosure parts and air guide pla-
tes; see M 35.00.
- Take off cylinder heads; see M 07.00.
- Detach fan and V-belt pulley from cranks-
haft; see M 13.00.
- Remove piston, conrod and cylinder; see
M 05.00 / M 06.00.
- Take off flywheel and connecting housing.
- Detach the timing case cover; see M 11.00.
- Take off the starter motor. 19
Dismantling:
- Remove machine screws and spring was-
hers for end cover and pull off the end co-
ver; see Fig. 19.
- Unscrew the machine screws(20/1) and

pull them out.
20
- Remove machine screws from crankshaft

gearwheel, loosen the gearwheel on the
crankshaft with a plastic-faced hammer
and pull it off.
- Pull out the locking collet (21/1).
21
L / M . . 01.97
3
- Unscrew and remove the hex bolts (22/1)
at both sides.
22
- The two halves of the crankcase are secu-
red together with straight pins (23/1). Drive
these back with a hammer and a suitable
drift until they are flush with the sealing
face. Lift the upper part of the crankcase
up vertically: Fig. 23.
Note:
To simplify the loosening and lifting off of the
upper part of the crankcase, insert two
M 8 x 65 machine screws (retaining screws
of setting-down device) at the timing end
and two M 14 x 50 hex bolts (used to secure
connecting housing) at the flywheel end in
the holes provided.
23
- Lift the crankshaft out of the lower part of

the crankcase.
- Carefully warm the balancing weight gear-
wheel 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 re-
move the flywheel-end counterweight, re-
move the machine screws for the gear-
wheel and drive out the straight pin (24/1).
24
L / M . . 01.97
3
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 inclu-
ded with the spare part.
- Renew the shaft sealing ring in the end co-
25
ver.
- 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 counter-
weight; 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“ mar-
king (25/2) on the gearwheel; see Fig. 25.
On the 4 L ... crankshaft, unscrew and remo-
ve the flywheel-end counterweight and ma- 26
noeuvre the balancing-weight gearwheel
into position as shown in Fig. 26.
- Apply sealant C to the straight pin (24/1)
and drive it in.
alt neu
- 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 intro-
duced. 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 cranks-
haft has been placed back in the lower part 5,5 6,5
of the crankcase.
27
L / M . . 01.97
3
- Place the thrust washers (28/1) on the
crankshaft so that the lubricating grooves
face the thrust face on the crankshaft.
Insert the bearing half-shells (28/2) into the
lower part of the crankcase, and apply oil
to them.
28
- Place the crankshaft in the lower part of

the crankshaft and make sure that the ge-
arwheels mesh together as indicated by
the marks.
For 2 / 3 L ... see Fig. 29.
29
- For 4 L ... see Fig. 30.
30
L / M . . 01.97
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- Insert the O-ring seal (31/1) for the main
oilway into the lower part of the crankcase.
Apply a thin, uniform coat of sealant B to
all areas of the joint line on the lower part
of the crankcase, and also on the interme-
diate webs of the crankcase;
see Fig. 31.
- Insert the bearing shells into the upper part
of the crankcase and coat them with oil.
31
- Position the thrust washers so that the

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

them to the specified torque in the order
shown in Fig. 33.
33
L / M . . 01.97
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- Check crankshaft endplay with a depth
gauge, Fig. 34, and compare it with the de-
sired value stated in Section 4.
34
- Drive the locking collet to secure the gear-

wheel (21/1) into the end of the crankshaft.
- Turn the camshafts until the two marks
(35/1) are aligned and the mark for the
crankshaft gearwheel faces downwards.
- Engage the crankshaft gearwheel, noting
the position of the mark, and tighten it to
the specified torque.
35
- Place the gasket (36/1) on the locking

collets.
- Insert a new shaft sealing ring and grease
its sealing lip.
Install the end cover, coat the machine
screws with sealant D and tighten them to
the specified torque.
36
L / M . . 01.97
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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
- Stand the upper part of the crankcase up,

take the circlip (38/1) out of the safety groo-
ve and press the valve tappet (38/2) off the
camshaft.
38
- Using a ∅ 47 mm driving-out sleeve, drive

the camshaft out towards the timing end
(see Fig. 39) and pull out the valve tappets.
39
L / M . . 01.97
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- Remove the circlip and shim washers and
pull off the ball bearing with a two-arm pul-
ler; see Fig. 40.
40
- If the gearwheel or camshaft is renewed,

use puller - 30 - with forcing-off screw - 31 -
to pull the gearwheel off the camshaft;
see Fig. 41.
Checking / repairs:
- Inspect the camshaft bearing points and
the bearing bores in the crankcase for sco-
re-marks and incorrect dimensions; for va-
lues, see Section 4.
- Check the camshaft gearwheel for score-
marks.
- Check the camshaft ball bearings for wear. 41
- Check the tappets for score-marks.
- Check the bores in the crankcase for the
tappets for score-marks and incorrect di-
mensions; for values, see Section 4.
Assembly:
- Heat the camshaft gearwheel to app. 150 -
200°C on a hotplate, and press it on.
- Place the circlip (42/1) in position and pull
on the ball bearing with impact sleeve - 9 -;
see Fig. 42.
42
L / M . . 01.97
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- When installing a new camshaft, make
sure that there is no endplay between the
ball bearing and the circlip (43/1).
If necessary, insert shim washers (43/2).
43
- Install the camshaft, noting the correct posi-

tions of the marks, and insert circlip (44/1).
- Drive the camshaft towards the timing end
of the engine until the ball bearing is in con-
tact with the circlip (44/1).
- Insert shim washers (43/3), push in cover
with O-ring seal (43/4) and attach circlip
(43/5).
Note:
- Check camshaft endplay; for values, see
Section 4.
If necessary, insert shim washers (43/3).
- A special camshaft has been introduced to
operate the valves on the following engi-
44
nes.
It can be identified by an “H” cast into the
camshaft.
2 M 31 H from No. 841087 000008
3 M 31 H from No. 851087 000004
4 M 31 H from No. 861087 000004
2 M 40 H from No. 781487 001631
3 M 40 H from No. 791487 000952
4 M 40 H from No. 801487 000873
L / M . . 01.97
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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.
- Remove the starting-mixture charging de-
vice; see M 12.00.
- Remove the fuel delivery pump.
Dismantling:
- See M 04.10.
Detaching the intermediate gearwheel:

Note:
The intermediate gearwheel can only be pul-
led off after removing the injection pump
camshaft.
- Take off the circlip (45/1) and unscrew the
splash plate (45/2). 45
- Pull off the gearwheel with the puller - 30 -

and the forcing-off screw - 31 - :
see Fig. 46.
Note:
The two ball bearings in the intermediate ge-
arwheel are separated by a circlip.
Checking / repairs:
- Check the camshaft bearing points and the
bearing points in the crankcase for score-
marks and incorrect dimensions; for valu-
es, see Section 4.
- Check the ball bearings for the camshaft
and the intermediate gearwheel for wear.
46
L / M . . 01.97
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Attaching the intermediate gearwheel:
Note:
The intermediate gear wheel must be instal-
led before the camshaft for the injection
pump is installed.
- Press the ball bearing into the intermediate

gearwheel and pull the gearwheel on using
impact sleeve - 9 - , noting the positions of
the markings; see Fig. 47.
- Place the circlip on the shaft.
47
Note:
Before pulling on, place the intermediate ge-
arwheel uniformly on the shaft, to prevent
the shaft from being pushed into the crank-
case.
Installing the camshaft:

- See ,,Installing camshaft for valve gear“
(M 04.10).
Note:
The camshaft for L 40/M 40 is marked
,,L 40“ next to the delivery pump drive cam.
L / M . . 01.97
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M 04.00 Camshaft
M 04.30 Governor and injection timer
- 30 - 31 - 40 -
Preparatory work:
- Removing camshaft for injection pump;
see M 04.20.
Dismantling the governor: (up to engine

serial number: 2 L 40.16, 3-4 L 40.15,
.M 40.12 and .L 30 and H.L 30)
- Remove circlip (48/1) and pull out gover-
nor spring (48/2).
- Detach spring from governor (48/3) and
push out pin (48/4) with roller sleeves
(48/5).
- Pull out spring sleeve (48/6) with pull rod
(48/7).
- Unscrew spring bridge (48/8) and take off
holder for governor weights (48/9).
Dismantling governor: (from engine serial 48

number: 2 L 40.17, 3-4 L 40.16, .M 40.13,
and all L 31 and M 31 engines)
- Remove circlip (48a/51) and pull out
spacing ring (48a/50), spring plate
(48a/49) and governor spring (48a/45).
- Remove the spring at the governor collar
(48a/11) and push out pin (48a/38) with rol-
ler sleeves (48a/37).
- Pull out the pull rod (48a/36), unscrew the
nuts (48a/44) and take off the spring plate
at the governor (48a/43), the locating was-
her (48a/42) and needle roller race
(48a/41), the shim washer (48a/40) and
the thrust washer (48a/39).
- Unscrew the spring bridge (48a/32) and
take off the holder for the governor weights
(48a/26). 48a
Checking / repairs:
- Check al parts for damage and signs of
wear.
L / M . . 01.97
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Pull off and dismantle the injection timer:
- Using puller - 30 - with pressing-off screw
- 31 -, pull the injection timer off the cams-
haft; see Fig. 49.
49
- Clamp the holder for injection timer assem-

bly - 40 - into the vise and place the hole in
the injection timer’s support disc on the
special tool; see Fig. 50.
50
- Turn the gearwheel counter-clockwise by

hand against the spring loading, and lift it
carefully off the support disc.
- Take off the centrifugal weights (51/1), re-
taining blocks (51/2) and pins (51/3) with
coil springs (51/4).
- Unscrew and remove the cam tracks
(51/5).
Checking / repairs:
- Examine the support disc and gearwheel
in the centrifugal weight area for score-
marks.
- Inspect the coil springs and their retaining
blocks for damage.
- Check the centrifugal weights for score-
marks.
51
L / M . . 01.97
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Assembling the injection timer:
- Assemble the injection timer by following
the dismantling instructions in the reverse
order.
Note:
The gearwheel and support disc were modi-
fied at the beginning of 1992.
Parts from the old and new versions cannot
be combined. 52
If necessary, renew the complete injection ti-
mer.
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.
- Turn the injection timer clockwise and al-

low it to move back to check its freedom of
movement; see Fig. 53.
53
- Coat the hole in the support disc with

sealant C and press the camshaft (with
shaft key) into the injection timer until the
gearwheel has 0.05 mm of endplay.
Note:
Check endplay with a feeler gauge as
shown in Fig. 54.
54
L / M . . 01.97
3
Assembling the governor:
- Assemble the governor by working the op-
posite order to that described for dismant-
ling; refer to Figs. 48 and 48a.
Note:
When assembling the governor, make quite
sure that all moving parts are able to move
freely.
On L/M 31/40 engines there must be a clea-
rance of 0.5 mm between spring plate
(48a/43) and nut (48a/44).
On L/M 41 engines the spring plate (48a/43) 55
must be held firmly when nut (48a/44) is
tightened.
- Install the spring for the governor (55/1) so

that the endface of the tapered section po-
ints in the direction of rotation.
Renewing governor spring:

(without detaching the timing case cover)
Preparatory work:
- Remove the engine shutdown device;
see M 20.00.
- On the H.L30 take off the cover;
see M 11.00.
Dismantling:
- Remove circlip (56/1) and spring plate
(56/2).
- Take out governor spring (56/3) and check
it for cracks or breakage.
Assembling:
- Choose the correct new governor spring 56
as stated in Section 4, according to the en-
gine’s intended use and speed range.
- Install the governor spring or engine shut-
down device by working in the opposite or-
der to that described for removal.
L / M . . 01.97
3
M 05.00 Conrod
- 35 - 36 -
Preparatory work:
- Take off the cylinder head; see M 07.00.
- Remove the cylinder and piston;
see M 06.00.
Dismantling:
- Unscrew and remove the big-end bolts
(62/1) and lift out the conrod and big end
cap with the aid of guide pin - 35 - or - 36 -.
Checking / repairs:
62
- Check the conrod bushing, big end bea-
ring and crankpin for score-marks and in-
correct dimensions; for values, see Section
4.
Assembly:
- Press the bushing into the conrod.
Note:
When pressing in the conrod bushing, make
sure that the oil holes are aligned and that
the bushing projects by an equal amount on
each side.
- Insert the big end bearing half-shells into
the conrod, making sure that the locating 63
nuts are in the grooves provided;
see Fig. 63.
- Install the big end cap, using guide pin
- 35 - or - 36 -; see Fig. 64.
- Attach the upper part of the conrod, insert
the big end bolts and tighten them to the
specified torque.
Note:
The groove (63/1) in the big end cap must
be on the side nearest the injection pump.
The groove (63/2) in the main conrod must
be on the valve tappet side.
64
L / M . . 01.97
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M 06.00 Piston and cylinder
- 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:
Checking cylinder wear and suitability
- Check the cylinder wall for seizure marks for further use:
or score-marks.
- Repeat the piston ring measuring proce-
- Check that the dimensions of the cylinder dure with a new piston ring.
are correct; for values, see Section 4.
- Compare the measurements obtained in
- Check the piston for seizure marks or ring this way with the maximum wear limits; if
web fractures. these are exceeded, the cylinder should
- Check piston ring end gaps; for values, not be re-used but an oversize cylinder
see Section 4. should be installed instead.
- If the measured values are within the li-
Checking piston ring end gaps: mits, the cylinder can be used again,
- Pull the piston rings off the piston. with new piston rings.
In this case, the cylinder wall must be
- Place each piston ring in its cylinder bore
roughened very slightly with a honing tool,
and move it to the TDC position of the pi-
since the honed finish will have been lar-
ston.
gely worn away after a lengthy period of
- Clean the piston crown and use it to positi- operation. If the cylinder were to be used
on the piston ring at a right-angle to the cy-
again without re-honing (whether the exi-
linder axis.
sting piston rings or new ones were fitted),
- Use feeler gauges to measure the piston excessive oil consumption would occur
ring end gap (where the ends of the piston and would not drop to the normal level af-
ring come together). ter a time, since the piston rings would not
- For limit values, see Section 4. be able to match themselves to the cylin-
der wall.
L / M . . 01.97
3
Procedure:
- While turning the honing tool in the cylin-
der, it must also be moved to and fro
axially.
Recommended speed of rotation approx.
350 rpm.
- Depending on the speed, the tool 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 pat-
tern can be clearly seen. It is normally ob-
tained after a honing time of approx.
20 - 45 seconds per cylinder.
- After honing, clean the cylinder with 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 in-
structions in the reverse order.
Note: 66
The recess in the piston crown must be loca-
ted towards the injection pump;
see Fig. 66.
- The piston ring gaps must be offset by

120° in each case; oil the piston rings in
their grooves.
- Attach clamping tool - 17 - and carefully in-
stall the cylinder; see Fig. 67.
67
L / M . . 01.97
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M 06.00 Piston and cylinder
M 06.20 Water-cooled engines (H.L 30)
- 16 - 17 -
Preparatory work:
- Take off the cylinder head; see M 07.00.
- Take off the alternator and water pump.
Dismantling:
- Carefully pull the cylinder off.
- Take out the piston pin circlip; see Fig. 68.
- Press the piston pin out by hand and lift off
the piston.
Checking / repairs:
- Examine the cylinder for seizure marks or
score-marks on the cylinder wall.
- Check cylinder dimensions and state of
wear; see Section 4.
- Inspect piston for seizure marks and ring
web breakage. 68
- Check piston ring end gap; see Section 4.
- Check piston ring end gap, cylinder wear
and suitability for further use;
see Section 4.
L / M . . 01.97
3
Installing:
Install the piston by following the removal
procedure in the reverse order as appropri-
ate.
Note:
The recess in the piston crown must be loca-
ted towards the injection pump;
see Fig. 69.
- The piston ring gaps must be offset by

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

and crankcase manufacturing tolerances; in
addition the gap is reduced to within a to-
lerance range of 1.0 - 1.5 mm.
- Attach shim plates 70/1 to the cylinder with

a small amount of grease.
- Oil the cylinder bore well. 70
Note:
If spare parts are obtained, the manufactu-
rer attaches the shim plates to the crank-
case or cylinder. They are not included in
the set of gaskets.
To order them separately, please quote the
following part numbers:
036 330 00 0.10 mm
036 388 00 0.15 mm
036 329 00 0.20 mm
L / M . . 01.97
3
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 pi-
ston; see Fig. 71.
71
- With the help of a second person, carefully

place the cylinder assembly in position and
insert auxiliary pins 621 646 00 into the
recesses on pistons ,,1“ and ,,3“; see Fig.
72.
- Lower the cylinder assembly and at the
same time move the auxiliary pins to and
fro until the pistons enter the cylinders.
- Take off the piston ring clamping tools and
move the centre piston to and fro during
the lowering movement until it enters its cy-
linder.
72
- The ring clamping strap is pushed into the
cylinder, and can then be pulled out of the
rectangular side opening in the crankcase
with the aid of a strong piece of wire.
Installing the cylinder assembly on the

H 2 L 30:
- Set both pistons to approximately the
same height and attach the piston ring
clamping tools.
- Further installation work is as described for
the H 3 L 30, but without the work relating
to the centre cylinder.
L / M . . 01.97
3
M 07.00 Cylinder head
Preparatory work:
- Take off the enclosure hood.
- Take off the exhaust-side enclosure and
the muffler (silencer); see A 03.00.
- Unscrew and remove the air outlet shaft,
side panel and cross-member;
see M 35.00.
- Unscrew and remove the cover plate and
take out the screws for the base plate; see
M 35.00.
- Take off the air cleaner.
- Remove the injector; see M 14.00.
73
Dismantling:
- Take off the cylinder-head (rocker) cover.
- Unscrew the shouldered nuts (73/1) and
bolts (73/2).
- Pull off the centering flanges (73/3).
- Detach the support plate mounts.
- Press the air guide housing and suction
shaft apart.
- Lift off the support plate; see Fig. 74.
- Detach the exhaust manifold and air intake
pipe.
Note:
To simplify dismantling of the air intake pipe,
it is best to unscrew and remove the air clea-
ner (74/1).
- Lift off the cylinder head and remove the

pushrod protective tubes.
Checking the cylinder head:

- Inspect for cracked webs or worn valve ta-
pers.
- Check the radius of the rocker pads for 74
wear.
L / M . . 01.97
3
Installing:
- Determine the gap between the cylinder
head and the piston at TDC.
Note:
This gap should be re-measured whenever
a cylinder, piston, conrod, crankshaft or
crankcase is renewed.
Measure at all cylinders, with the engine
cold.
- Clamp the cylinder down with a suitable

tensioning strap, and use a depth gauge;
see Fig. 75.
75
b S a
- Turn the engine over until the piston re-
aches and passes through top dead centre
(TDC).
- Measurement ,,a“ plus the thickness of gas-
ket ,,b“ yields the gap dimension ,,S“ stated
in Section 4; see Fig. 76.
76
L / M . . 01.97
3
- Having established the correct gasket
thickness, coat it with a little grease on the
cylinder head side, and place it in the cen-
tering collar on the cylinder head.
Note:
Centering on the L 30 is not by means of a
centering collar but with centering sleeves;
the gasket has two centering holes;
see Fig. 77.
77
- Insert the protective tubes (78/1) with

spring (78/2), thrust rings (78/3) and O-ring
seals (78/4) into the bore in the crankcase.
Note:
Always renew the O-ring seals (78/4) during
cylinder or cylinder head repairs.
- Insert the pushrods (78/5).
78
- Attach the cylinder head, making sure that

the protective tubes with O-ring seals enter
the corresponding holes in the cylinder
head correctly; see Fig. 79.
- Oil the stud bolt threads (79/1) and screw
on the shouldered nuts.
Note:
Apply sealant D or a permanently elastic
sealant to the thread of stud bolt (79/2) and
the shouldered nut contact face (79/3).
79
L / M . . 01.97
3
- Screw the cylinder head on until it is rest-
ing evenly on the cylinder, but without final
tightening.
- Align the cylinder head by attaching the ex-
haust 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 va- 80
lues.
- Further installation work is as described for
removal, but in the reverse order.
L / M . . 01.97
3
M 07.20 Overhauling cylinder head (air-cooled engines)
-1-2-6-7-
Preparatory work:
- Removing cylinder head - see M 07.10.
Dismantling cylinder head:
- Place the cylinder head on the centering
collar.
Note:
On the L 30, pull out the centering sleeves
(81/1).
The cylinder head sealing face must not 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 hou-
sing (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 81
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 co-
nes for wear; for valve recess into cylinder
head, see Section 4.
- Check correct dimensions of rocker bush-
ing, rocker shaft and rocker pad radius; for
values, see Section 4.
L / M . . 01.97
3
Assembling cylinder head:
- If necessary, use a pressing-in tool - 1 - to
force out the valve guides; see Fig. 82.
- Use the pressing-in tool again to insert the
new valve guides - 1 -.
Note:
The correct pressing-in depth must be com-
plied with; for projection, see Section 4.
82
- Using a hand-held reamer - 2 -, ream out

the valve guides to their nominal diameter;
see Fig. 83.
83
- Re-machine the valve seats with a valve

seat milling cutter; see Fig. 84.
Note:
The valve seat must always be re-machined
after installing new valve guides or before in-
stalling new valves, but no more metal than
absolutely necessary (no patches anywhere
on circumference of valve seat).
84
L / M . . 01.97
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- Insert valves into valve guide.
Lap the valve cones with grinding paste
(grade: 180-250).
Note:
To check the lapped valve seats, clean the
valves, insert them and pour a small amount
of diesel oil into the inlet and exhaust ports.
No fuel should seep through past the valve
seats.
Assembling the cylinder head:

- To assemble the cylinder head, follow the
dismantling instructions in reverse as ap-
propriate.
Note:
- Engines built in 1979 - 1983 have one
spring per valve; from 1984 onwards, two
springs per valve were installed. If repair
work is carried out in this area, the second
valve spring should be retrofitted.
- On M 31/M 40 engines up to 2300 min-1,
cylinder heads with the code letter ,,H“
(high swirl) are used; above 2300 rpm the
cylinder head code letter is ,,L“ (low swirl).
These code letters are stamped in the inlet
port.
- On engines built from mid-1986 on with a
running speed below 2300 rpm the longitu-
dinally slotted rocker and valve stem seal
adjusting screws are used; these screws
were installed on all engines from mid-
1989 onwards. Retrofit these screws if re-
pairs are carried out.
- Before pressing on the valve stem seals,
insert the valves into the valve guides.
Press the seals on with assembly tool - 7 -.
L / M . . 01.97
3
M 07.30 Water-cooled engines (H.L 30)
Preparatory work:
- Drain the coolant and unscrew the coolant
lines from the cylinder head.
- Take off the exhaust system and exhaust
manifold.
- Take off the air cleaner and detach the air
intake flange.
- Remove the injectors.
Dismantling:
- Take off the cylinder head cover; Fig. 85. 85
- Slacken off the shouldered nuts by half a
turn (85/4) in the reverse of the order
shown in Fig. 86 or 87.
- Unscrew and remove the nuts in the same
order.
Unscrew the hex nuts (85/5) with spring
washers (85/6) and take off the rocker pe-
destals.
- Lift off the cylinder head.
- Take off the pushrods and protective tubes.
- Take off the cylinder head gasket and sea-
ling rings.
Checking the cylinder head: 86

- Visual inspection for cracks in webs.
- Visual inspection of cylinder head sealing
face for unevenness.
- Check pad radius on rockers for wear.
87
L / M . . 01.97
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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 88
them.
- Coat the thread of the tierod in the oil ca-
vity 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 alumi-
nium pushrods is 0.40 mm, for engines with
steel pushrods 0.20 mm.
- Further installation is by following the remo-

val instructions in the opposite order.
L / M . . 01.97
3
M 07.40 Reconditioning the cylinder head (water-cooled engines)
-1-2-6-7-
Preparatory work:
- Remove the cylinder head; see M 07.30.
Dismantling the cylinder head:

- Remove the circlips (89/10) from the
rocker pedestal and pull off the rocker
(89/11) with shim washers (89/12).
- Pull out the centering sleeves (89/1) and
place the cylinder head on its sealing sur-
face.
Note:
Do not scratch or otherwise damage the cy-
linder head sealing face; always place a soft
cloth or similar underlay beneath it.
- Press the spring plate (89/2) down with

tool - 6 - and remove the valve spring
collets (89/3).
- Take out the valve springs (89/4) with un-
derlay washers (89/6).
Note:
Engines with a running speed of less than
2300 rpm. are equipped with adjusting
screws with longitudinal slots for the rockers
(89/13) and valve stem seals (89/5).
89
You are recommended to retrofit these
screws during subsequent repair work.
Engines built up to and including 1983 (all
running speeds) have single valve springs.
During repairs you are recommended to in-
stall double valve springs on engines which
run at more than 2300 rpm.
- Place the cylinder head on the exhaust
side and pull out valve cones (89/16
and 17).
- Take off cover (89/7) with sealing ring
(89/8) and take out thermostat (89/9).
L / M . . 01.97
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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 sur-
face.
- Examine the valve seat rings and valve
collets for wear. Note valve recess in head;
90
see Fig. 90 and Section 4.
Reconditioning cylinder head:

- If necessary, press the valve guides out
with pressing-in tool - 1 -, Fig. 91.
- Press in new valve guides with the same
tool - 1 -.
Note:
The pressing-in depth must be correct; for
projection, see Fig. 92.
- Ream out the valve guides to nominal dia-

meter with hand-held reamer - 2 -,
Fig. 91.
- If the valve seats are leaking or have been
91
damaged locally, or after installing new val-
ve 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 pa-
ste, grain size 180 - 250); see Fig. 91.
92
L / M . . 01.97
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Note:
- To check the lapped valve seats, clean and
install the valves, then pour a small quan-
tity of diesel oil into the inlet and 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, in-

sert the valves into the valve guides. Press
the seals on with assembly tool - 7 -.
L / M . . 01.97
3
M 10.00 Oil pump
- 13 -
Preparatory work:
- Take off the timing case cover;
see M 11.00.
Dismantling:
- Take out the machine screws (97/1) and lift
off the oil pump.
- If necessary, pull out needle roller bearing
(98/1) with an internal puller.
Checking / repairs:
- Examine the contact face for the shaft sea-
ling ring for score-marks.
If the contact face is worn, a ,,wear sleeve“
can be pushed over it. Use sealant E for
this purpose.
Installation instructions are included with
the spare part.
Assembly:
97
- Using a plastic-faced hammer, drive the
needle roller bearing flush into the crankca-
se.
- Insert the oil pump with bearing journal into
the needle roller bearing and place it over
the centering sleeves.
- Insert and tighten the machine screws.
Note:
- Apply sealant D to the machine screw for
hole (98/2).
- Coat the endface of the oil pump which is
in contact with the crankcase with sealant
B.
- Re-assemble the engine in the opposite or-
der to that described for dismantling.
- When renewing the oil pump, make sure
that the correct type is installed
(2- / 3- or 4-cylinder engine).
98
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Checking oil pressure:
- Unscrew the oil pressure sensing switch
and connect an oil pressure gauge with fle-
xible hose - 13 - .
- Install the side panel and enclosure hood.
- Start the engine and compare the oil pres-
sure when it is at regular operating tempe-
rature. At n = 800 rpm min. 0.9 bar,
see Fig. 99.
- Before assembly, coat the thread of the oil
pressure sensing switch with sealant D.
99
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M 11.00 Timing case cover
Preparatory work:
- Take off the exhaust silencer (muffler);
see A 03.00.
- Take off the air guide housing;
see M 35.00 (engines with enclosure only)
- Take off the fan; see M 13.00.
- Take off the engine shutdown device;
see M 20.00.
Dismantling
Timing case cover without hydraulic
pump drive:
- Pull the hose off the crankcase breather 100
valve (100/1).
Note:
From 2 L 40.14, 3/4 L 40.13, M 41 and on
the M 31, M 40 and M 41 the hose connecti-
on (101/2) for the crankcase breather has
been moved to the top of the crankcase.
The valve (101/1) was bonded into the air in-
take pipe until early 1987. Since then it has
been secured in the air intake pipe by two
O-rings.
- Remove the circlip (102/1) and coil spring
(102/2) from the pull rod of the engine shut-
down device.
From early 1996 an additional cup spring 101
and an O-ring have been installed to seal
the pull rod.
- Unscrew and remove the belt pulley
(102/3) and the machine screws holding
the timing case cover all round.
- Pull off the timing case cover and remove
the gasket.
Checking parts:
- Check the timing case cover for cracks or
unevenness of the sealing surface.
- Examine the shaft sealing ring for damage
and renew if necessary.
- Press off the breather valve cap and exami-
ne the diaphragm for damage. 102
L / M . . 01.97
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Dismantling
Timing case cover for hydraulic pump dri-
ve:
Additional work:
- Take off the hydraulic lines and hydraulic
pump.
- Pull out the driver (103/1).
- Remove both machine screws (103/2)
including spring washer (103/3), plate
(103/4) and gasket (103/5).
- After removing the timing case cover retai-
ning screws (103/4) and taking off the ti-
ming case cover (103/6) the support mount 103
(103/9) is exposed and can be taken off af-
ter 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. 104
Assembling:
- Apply grease to the contact edge of the
shaft sealing ring.
- Before fitting, coat new seals on both sides
with sealant H.
- Install the timing case cover.
- On the 2 and 3 L ... insert M 8 x 12 machi-
ne screws into holes (105/1) and (105/2)
with sealant D.
105
L / M . . 01.97
3
- Further timing case cover attachment and
engine assembly procedures are as descri-
bed for removal, but working in the reverse
order.
Note:
When renewing the breather valve, secure
the new valve housing in the insert (105/3)
with sealant E and then seal all round with
sealant H.
If the insert is renewed, use sealant C for
bonding in.
The hose spigot opening in the air intake
pipe must face toward the intake port of
cylinder 1.
The position of the opening can be varied by
inserting or removing spacing washers (only
on engines with crankcase breather in ti-
ming case cover).
L / M . . 01.97
3
M 12.00 Extra-fuel device
M 12.10 with injection pump PFR 1K 80
Preparatory work:
- Detach the enclosure hood and side panel;
see M 35.00.
- On twin-cylinder engines, detach the oil
filler pipe.
Dismantling:
- Remove the screws for the extra-fuel de-
vice and take it off; see Fig. 106.
Dismantling the hydraulic extra-fuel de-

vice::
- Take off the circlip (106/1), unscrew the
threaded pin (106/2) and push out cylinder
(107/1).
- Take off the circlip (107/2) and pull out the
end cover (107/3) and the piston (107/4)
with spring (107/5).
106
- Take out circlip (107/6) with spring plate
(107/7), spring (107/8) and ball (107/9).
Checking / repairs:
- Inspect the piston and cylinder of the extra-
fuel device for score-marks or worn areas.
- Check the ball seat of the pressure relief
valve for wear marks.
- Renew the O-ring seals.
Assembling the hydraulic extra-fuel de-

vice:
- Assembly is as shown in Fig. 107, working
in the opposite order from dismantling.
107
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Checking the extra-fuel device:
- After assembly, check free movement of
the extra-fuel device’s piston by pulling it
out and letting it slide back; see Fig. 108.
108
Attaching:
- The extra-fuel device is installed by follow-
ing 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 seal-
ant 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 eccentri-
cally located in the cylinder (107/1).
The effective stroke and therefore the maxi- 109

mum injected fuel volume are adjusted by
turning this cylinder.
For effective stroke requirements and adjust-
ing 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.
L / M . . 01.97
3
- 34 -
Preparatory work:
- see M 12.10.
Dismantling:
- Pull terminal 7 off the solenoid valve (only
version with electric engine shutdown).
- Remove the screw (111/28) with sealing
rings (111/36).
- Make a scribed mark on the crankcase
and the monitoring block, so that the moni-
toring block can later be re-attached in the 110
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 so-
lenoid valve (110/21) and take it off comple-
te with sealing ring (110/23), armature
(110/24) and spring (110/25).
- Remove the screw plug(111/8).
- Take off the lock washer (111/26), pull up
shaft (111/12) take out lever (111/15), 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).
111
L / M . . 01.97
3
Checking parts:
- Examine the piston for score marks or
wear.
- Check the valve seat (111/19) for wear.
- Renew the O-rings.
Assembling the engine monitoring block:

- Proceed in the opposite order of work to
that described for removal.
Note:
To install the piston, use auxiliary bushing
- 34 -.
Assembly:
- Move the speed control lever to the ,,Stop“
position.
- To attach, follow the instructions for de-
taching the device in the reverse order.
- Make sure that the gasket is correctly sea-
ted and note the scribed mark which indica-
tes the correct position; install the 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 monito-
ring 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 adju-
sted 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 deta-
ched and re-attached, the fuel injection vo-
lume need not be adjusted, provided that
the setting of piston (111/18) was not alte-
red.
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
3
M 12.30 with PFR 1K 90 injection pump (from L / M 31.12, M 40.16, 2 L 40.19,

3-4 L 40.18 and L / M 41)
- 34 -
Preparatory work:
- see M 12.10.
Dismantling:
- Detach plug connector (164/1) from engine
wiring harness (electric version only).
- Take out machine screws (164/3) and de-
tach cover (164/4) and solenoid valve
(164/5) with gasket (164/6).
- Make a scriber mark on the crankcase and 164
the servo block to ensure that they are in-
stalled 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 165
(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.
166
L / M . . 01.97
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Dismantling the servo block:
- Take off lock washer (164/7).
- Hold piston (164/8), raise shaft (164/9) and
take out sickle-shaped lever (164/10).
- Release piston (164/8) carefully and take it
out of the housing.
- Drive out locking collet (164/11) and pull
shaft (164/9) out of the housing.
- Take out grub screw (164/12).
- Remove circlip (164/13) and take out was-
her (164/14) and eccentric disc (164/15).
Checking / repairs: 167

- Examine piston for wear or score marks.
- Renew gaskets. Warning:
The sickle-shaped lever must never be
Assembling the servo block: under or to the right of the stop.
- Assemble in the opposite order of work to - Screw the block on tightly.
that described for removal. - Set the speed control to the ,,Start“ positi-
When installing the piston, use bushing on and move piston (167/8) to and fro be-
- 34 -. tween the start and stop positions. With
Note correct position of gasket (164/6) (oil the injection pump removed or the side
hole). cover taken off, the governor lever can
Apply sealant D to machine screws (164/3) be seen to perform the same movement.
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 positi-
ons; attach a lead seal.
When attaching the monitoring block,
make sure that sickle-shaped lever (166/4)
is located at the left of stop (166/5).
L / M . . 01.97
3
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 be-
tween bores 3 and 4.
- Apply the electric current to connection ,,3“
168
(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.
169
L / M . . 01.97
3
M 13.00 Fan
Preparatory work:
- Take off the exhaust-system capsule (en-
capsulated 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 alter-
nator.
- 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
3
M 14.00 Injection pump, functional check
-5-
Preparatory work:
- Take off the capsule hood and side panel.
- Detach the fuel delivery pipes from all in-
jector pumps, holding the pipe union to pre-
vent it from turning.
Check injection pumps:

(Fig. 182)
- Attach test nozzle - 5 - with delivery pipe to
the injection pump you wish to check.
- Cover the pressure valve holders on the
other injection pumps with absorbent clea-
ning cloths.
- Move the speed control lever to the start
position and run the starter.
If the spray pattern is correct, the pump you

have checked is in good mechanical wor-
king order (no pump element wear, no leaka-
ge at pressure valve).
182
WARNING!
Keep hands away from the injected fuel
spray.
The fuel spray from the injector nozzle can
cause blood poisoning if it contacts the skin.
L / M . . 01.97
3
Preparatory work:
- Take off enclosure hood, side panel and co- - Unscrew and remove the extended stub
ver for air guide housing; see M 35.00. bolt or machine screw (119/2) at the in-
- Take off fuel filter and fuel delivery pump. jection pump for cylinder 1. This also
- Take off guide plate for oil cooler on S/Z. acts as a travel limiter for the governor
- On engines with shutdown solenoid, to re- rod.
move pump for cylinder 1 take off the star- Note:
ting charge device including the solenoid This device is not fitted to older engines.
(see A 11.00); on the two-cylinder engine, - Disconnect tension spring (120/1) at the
also take off the oil filler pipe. governor rod (120/2) and pull out the go-
vernor rod guide (120/3) with packing
Removing the injection pump: seals.
- Set the speed control lever to a central po-
sition.
- Remove the hex nuts for the injection
pump mounting, and pull out the injection
pump.
- Take off the shim washers.
Note:
- Do not install the shim washers at the
wrong points.
- On four-cylinder engines, the hollow
restrictor screw for the injection pump at
the timing end has a return-flow restrictor.
During repairs, make sure that the correct 119
hollow screw is used, or else the volume of
fuel in the injection pump will be altered.
Removing the governor rod:

- Take off the oil filler pipe, the starting char-
ge control device and all side covers.
- Using water pump pliers, press out locking
pin (119/1) until the governor lever can be
moved to the flywheel end; see Fig. 119.
120
L / M . . 01.97
3
- Drive locking collet (121/1) halfway into the
pull rod with a suitable split pin driver.
- Turn the pull rod through 180° and pull out
the locking collet with water pump pliers.
- Take off the Poly-V-belt; see M 20.00.
(The pull rod will be pulled out.)
121
- Pull the governor rod out towards the

flywheel end; see Fig. 122.
Note:
To remove the governor rod on Types ,,C“
and ,,K“, the rear enclosure panel must be ta-
ken off.
Checking parts:
- Check the governor rod for score-marks in
the governor rod guide area.
Installing the governor rod:

- Install the governor rod by following the in- 122
structions for its removal in the reverse or-
der.
- 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 gover-
nor rod guide.
123
L / M . . 01.97
3
- Using the speed control lever, locate the
governor rod so that the groove for the too-
thed rack pin on the flywheel-end injection
pump is precisely in the centre of the mo-
unting hole for the injection pump in the
crankcase; see Fig. 124.
- Check the position of the other grooves
and if necessary reposition the sliding ele-
ments on the governor rod.
- Insert the injection pumps and tighten
them in position.
- For adjusting work, see M 14.50.
124
Note:
When installing the injection pumps, use the
shim washers at the points from which they
were previously removed. The figure stam-
ped next to the injection pump indicates the
thickness of the shims,
e.g. 75 = 0.75 mm.
L / M . . 01.97
3
- 27 -
Preparatory work:
- see M 14.10.
Removing the injection pump:

- Insert locating pin - 27 - into the hollow-dril-
led stud bolt of pump 1 to lock the gover-
nor rod in the ,,X“-Position (141/1).
- Remove the hex nuts and spring washers
securing the injection pump.
- Pull out the injection pump.
- Take off the paper gaskets and shim was-
141
her.
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. 170
- Install in the reverse order of work.
Note:
When installing the governor rod, the stop
pin for the governor rod (126/2) must enga-
ge between the governor lever (126/1) and
the leaf spring (126/3).
126
L / M . . 01.97
3
Installing the injection pump:
- Connect the governor rod in the ,,X“-positi-
on.
- When installing the injection pumps, use
the same shim washers and gaskets as
before.
- Insert the injection pumps and, 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 crank-
case (127/1).
Note:
127
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. Ne-
ver use more than one steel shim washer.
How to make up the seal pack:
Total Paper Steel

thickness gasket washer
(mm) (mm) (mm)
0.2 0.2 –
0.3 0.3 –
0.4 0.2 + 0.2 –
0.5 0.3 + 0.2 –
0.6 0.3 + 0.3 –
0.7 0.2 + 0.2 0.3
0.8 0.3 + 0.2 0.3
0.9 0.3 + 0.3 0.3
1.0 0.2 + 0.2 0.6
1.1 0.3 + 0.2 0.6
1.2 0.3 + 0.3 0.6
1.3 0.2 + 0.2 0.9
1.4 0.3 + 0.2 0.9
1.5 0.3 + 0.3 0.9
1.6 0.2 + 0.2 1.2
1.7 0.3 + 0.2 1.2
1.8 0.3 + 0.3 1.2
L / M . . 01.97
3
M 14.30 Injector
- 4 - 37 -
Preparatory work:
- Take off the enclosure hood and side pa-
nel; see M 35.00.
Removing:
- Unscrew and remove fuel pressure pipe
(128/1) and oil leak-off line (128/2).
128
- Unscrew and remove loop for injector

(128/3). Take out the injector and sealing
ring (129/1) using impact extractor tool
- 4 -.
Functional check:
- Connect extension tube with test pressure
gauge for fuel injection system - 37 - to the
pressure tube connection for the injection
pump; see Fig. 129.
- Connect the injector to the tester, cover the
remaining injection pumps over with clean
cloths and start the engine.
Note:
All injectors should be removed for this test.
WARNING:
Keep the hands away from the fuel spray
emerging from the injectors.
The fuel spray from the injectors can cause
blood poisoning.
129
L / M . . 01.97
3
- Check the spray pattern from the injector
as shown in Fig. 130.
Assembling:
- Install the injectors using new sealing rings
and working in the opposite order to that
described for their removal.
Note:
- Place the seal on the injector so that the
soft, graphited side is at the top, towards
the injector.
130
- Tighten the hex nuts to retain the injector
and the collar nuts on the pressure pipe to
the specified torques (see Section 4), hol-
ding the pressure pipe connection on the
injection pump to prevent it from turning.
- The fuel pressure pipes from 2 L 40.17, 3/4
L 40.16, M 40 L.13 and M 31 L have a
smaller internal diameter and are identified
by the section of hose pushed on to them.
L / M . . 01.97
3
M 14.40 Injector nozzle
Preparatory work:
- Remove the injector; see M 14.30.
Dismantling:
- Take off the collar nut (132/1) and remove 7
the nozzle with needle (132/2).
- Take out spacer (132/3), pressure pin
(132/4), spring (132/5) and shim washers 6
(132/6).
5
Checking parts:
- Inspect the needle of the nozzle for score- 4
marks or signs of overheating.
- The nozzle needle (132/2a) must, when 3
the nozzle is held vertical, slide down slo-
wly and smoothly under its own weight on 2a
to its seat.
- Renew the nozzle if necessary. 2
- Check the sealing faces on the nozzle hol-
der for damage.
Assembling: 1
- Install the shim washers, spring, pressure
pin and spacer in the nozzle holder again
as shown in Fig. 132, in the opposite order
from their removal. 132
- Attach the injector nozzle so that the pins
on the spacer locate in the holes on the
nozzle.
- Screw on the collar nut and tighten it.
- Mount the injector on the tester and deter-
mine its fuel delivery pressure; for values,
see Section 4.
- Correct the fuel delivery pressure by inser-
ting shim washers:
Thicker washers = higher delivery pressure
Thinner washers = lower delivery pressure
0.15 mm ≈ 15 bar.
L / M . . 01.97
3
M 14.50 Adjustment work with PFR 1K 80 injection pump

(up to 2 L 40.16, 3-4 L 40.15, M 40.12, also L 30 and H.L 30)
- 10 - 11 - 29 -
Nature of repair Adjustments Notes

needed
Removing and installing Install shims again at the

or exchanging com- point where they were removed
plete injection pump
Synchronising
Repairing Injection pump must only be repaired
injection pump by authorised workshop
Renewing camshaft Start of injection

for injection pump Measure effective stroke
Synchronising before removal and restore
Renewing crankcase when installing
Effective stroke
Removing and installing Synchronising

governor rod
Synchronising Measure effective stroke
Renewing governor rod Effective stroke before removal and restore
when installing
Measure effective stroke

Renewing starting charge Effective stroke before removal and restore
control when installing
Conversion from injection-

pump with control lip at top Start of injection
(start of series production) All pumps on the engine
to pump with control lip at Synchronising must be converted
bottom (current series
production status) Effective stroke For adjustment data see Section 4
Modifying the Effective stroke Measure the original effective

power setting stroke. Alter effective stroke
only by difference value
L / M . . 01.97 3
1. Adjusting start of fuel delivery:
Note:
Start the adjustment at the timing-end injecti-
on pump.
- Move the speed control lever to the full-

load position and secure it there.
- Remove the pressure tube connection and
pressure valve at the injection pump.
- Screw the overflow device - 10 - into the in-
jection pump.
- Screw the extension pin of the overflow de-
vice into the dial gauge - 11 - and insert 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
- Turn the crankshaft in the normal direction
of rotation (counter-clockwise when loo-
king at the flywheel), until the dial gauge
needle starts to move.
- Open the fuel feed; fuel will emerge from
the overflow device.
- To turn the engine over, attach a ratchet
with 1/2-inch square end to the square
recess in the belt pulley.
- Continue to turn the engine over slowly un-
til the fuel emerges from the overflow pipe
slowly as separate droplets
(about. 1 droplet every 5 - 6 seconds).
- This point is the start of fuel delivery.
L / M . . 01.97
3
- Read the angle in degrees at the inspecti-
on hole in the connecting housing, and
compare it with the desired value in Secti-
on 4. To take the reading, remove the pla-
stic 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 ang-
le in degrees is only stamped on the engi-
ne for the first (timing-end) cylinder; only
two marks are provided for the other cylin-
ders.
The short mark (half diameter of inspection 134
hole) shows the angle for the start of deli-
very, the long mark (full diameter of in-
spection hole) shows the piston top dead
centre point.
- If necessary, correct the start of fuel deli-

very 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 va-
lue:
= fuel delivery starts too soon.
Add more shims.
Note:
Use a dial gauge as follows to determine the
thickness of the shims needed to correct the
value:
- Set the dial gauge to “0" at the actual start

of fuel delivery, and turn the flywheel to the
desired start of fuel delivery.
The dial gauge will now show the thick-
ness of the shims to be inserted or remo-
ved.
- Repeat the measurement procedure; the
fuel drip from the overflow pipe on the adju-
sting device must start precisely when the
desired value is reached.
- Carry out the measuring procedure at all in-
jection pumps.
L / M . . 01.97
3
2. Adjusting end of fuel delivery:
Note: Note for engines from serial number

Engines equipped with Type PFR 1K 80A L 30.17, 2 L 40.15, 3 / 4 L 40.14, M 40.11
439/2 injection pumps must be adjusted to on:
the correct end of the delivery stroke.
The governor rod travel limit screw
- Prepare for the measuring procedure in
(135/2) must be unscrewed during this
the same way as if the start of fuel delivery
work, or else the ,,Stop“ point for the pump
is to be measured.
governor rods will not be reached.
- 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 over-
flow pipe again
(about 1 droplet every 5 - 6 seconds).
- This point is the end of fuel delivery.
- The value obtained in this way must agree
with the desired value stated in Section 4.
- If necessary, correct it as described above.
3. Synchronising injection pump delivery

volume:
- Move the governor rod by hand fully to the
right, to the ,,Stop“ position, and hold it the-
re.
- Loosen all sliding elements (135/1) on 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 in-
jection 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 coa-
ting to the starting charge device, to ensu-
re that its oilway is not blocked when as-
sembling.
- Coat all bolt threads for the cover and star-
ting charge device with sealant D. 135
L / M . . 01.97
3
4. Adjusting effective stroke:
(on engines with start of delivery ad-
justment)
- Install the start charging device and re-
place the cover by hydraulic starting char-
ge adjuster 619 845 00;
see Fig. 136/3.
- Set the speed control lever to full load 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 mo-
136
ves from “0" to precisely the nominal ef-
fective stroke value stated on the type pla-
te.
- In this position, fuel should start to drip 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 slo-
wly.
- When the setting is correct, retighten grub
screw (136/2), seal it with lacquer and in-
stall the cover again in place of the adju-
ster (136/3).
L / M . . 01.97
3
5. Adjusting the effective stroke
(on engines with end-of-delivery ad-
justment):
- Prepare for the adjustment in the same
way as described for start-of-delivery ad-
justment.
- Set the injection pump to the end of fuel de-
livery.
- Turn the crankshaft in the opposite directi-
on to normal rotation until the dial 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 connecti-
on and tighten to the specified torque.
137
6. Note on changing the power setting:

- Measure and make a note of the original power setting. Remember that as a result of
tolerances the actual effective stroke setting may not coincide exactly with the 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: 1.14 mm

– Effective stroke for power output B from table: 1.07 mm
Difference between effective stroke values: 0.07 mm
Effective stroke measured at engine: 1.05 mm
+ difference value 0.07 mm
New effective stroke setting: 1.12 mm
L / M . . 01.97
3
M 14.60 Adjustment work with PFR 1K 90 injection pumps

(from engine serial numbers 2 L 40.17, 3-4 L 40.16, M 40.13
on L 31 / 41 and M 31 / 41: all engines)
- 23 - 24 - 25 - 26 - 27 - 28 -
Inst. work Work needed on fuel injection system
Renew injection Start of injection (with shims);

pump precise radial position of pump
Marking crankcase with radial position of

Renewing
injection pumps
governor rod
Adjusting injected volume for nominal power output
Renewing start Adjusting injected volume for nominal power output

charge control Adjusting damper spring (generator operation only)
Renewing
governor lever
Renewing Marking crankcase for adjustment of start

injection pump of fuel injection
camshaft Adjusting start of fuel injection
Marking crankcase for adjustment of start

Renewing of fuel injection and radial position of injection pumps
crankcase Adjusting start of fuel injection
Adjusting max. idle speed

Altering nominal engi-
Varying 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 3
1. Crankcase mark for adjusting start
of fuel delivery:
- Insert measuring device - 25 - into the cali-

brating 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 moun-
ting 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 138
mark on the flywheel (15° before TDC) for
the cylinder in question is aligned with the
fixed mark on the crankcase or in the in-
spection hole of the connecting housing;
see Fig. 134.
- In this position, take the total dial gauge
reading; see Fig. 139.
139
- From this total dial gauge reading, deduct
2.15 ± 0.05 mm and stamp the remaining
value (without +/- sign or decimal point)
into the crankshaft as a tenths of millimetre
value (140/1).
Repeat this procedure for each pump mo-
unting hole.
140
L / M . . 01.97
3
2. Marking the crankcase for the radial
position of the injection pumps:
- Insert the locating pin - 27 - into the hollow-

drilled stud bolt of pump 1 to lock the go-
vernor rod in position ,,X“ (141/1).
- Insert the marking device - 23 - into the in-

jection pump mounting hole, turn clockwise
to make proper contact and stamp the 141
mark on the crankcase; see Fig. 142.
Make this mark for each injection pump
mounting hole.
3. Adjusting injection volume for nominal

power output (engine stopped)
- Move the speed control lever to the ,,Stop“

position.
- Remove the screw plug from the monito-
ring block housing or replace the valve so-
lenoid by the plate of the adjusting tool -28-
, then use a depth gauge to measure the
distance ,,S“ from the outer edge to the flat 142
face on the piston inside; see Fig. 143.
- Screw in the injection volume adjusting
tool - 28 -, using a number of copper sea-
ling rings according to the following table:
S(mm) Number of sealing rings

≤ 11.3 2
>11.3 1
see also Fig. 143.
143
L / M . . 01.97
3
- Remove the second injection pump (loo-
king from the timing end) and install mea-
suring 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 star-
ting position.
- Insert locating pin - 27 - into the hollow-dril-
led stud bolt, then turn the adjusting screw 144
slowly clockwise until the locating pin enga-
ges under light pressure in the correspon-
ding 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 un-
til the dial gauge shows the control distan-
ce needed. Do not forget to allow for the 145
0.01 - 0.02 mm already indicated by the
dial gauge.
Note:
A minus value (= lower power range) is ob-
tained by turning the adjusting tool clockwi-
se, a plus value (higher power) by turning
counter-clockwise.
- Tighten the grub screw (146/1) carefully to

prevent this setting from being lost, and
secure it with lacquer.
146
L / M . . 01.97
3
- 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 gover-
nor rod travel setting plus (for increased power) or minus (for decreased power) the diffe-
rence from the adjustment data.
Example:
To change a 3 M 40 engine (n=3000 rpm) from power output B to power output F.
Governor rod travel for output F acc. to adjustment data: +0.13 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 engine’s running speed is to be altered (with or without a change in power output),
the following work is needed:
- Set the engine speed to the new value.
- Move the governor rod to position ,,X“ and set the dial gauge to ,,0“.
- Turn the adjusting tool - 28 - until the dial gauge shows the governor rod travel called for
according to the type plate or adjustment data.
4. Adjusting the damping spring (generator operation, PV 187)

This adjustment can only take place with the engine running at the upper idle speed limit
and off-load. In addition, the engine must have reached its regular operating temperature,
or else the speed setting will not be accurate.
- Turn the stop screw for the upper idle speed limit (146/2) until this speed is about 0.3 %
lower than the desired value according to the type plate.
Example:
Type plate data 3000/60 = 3060 - 0.3 % = 3050 rpm. Make sure that the damping spring
is not yet touching the governor lever. Unscrew the grub screw (146/3) at the monitoring
block until no change in engine speed is detected. After this, retighten the grub screw
(146/3) until the upper idle speed rises again by the same value of app. 0.3 %.
L / M . . 01.97
3
M 17.00 Flywheel
Dismantling:
- Remove bolts (148/3) and disc (148/2).
- Screw in two suitable stud bolts to act as
guides.
- Take off the flywheel.
Assembling:
- Drive locking collet (148/1) into the end of
the crankshaft at the flywheel end to pro-
vide the necessary centering action.
- Attach the flywheel so that the locking 148
collet enters the centering hole.
- Place the disc (148/2) in position, insert
the bolts (148/3) and tighten them to the
specified torque.
L / M . . 01.97
3
M 20.00 Engine shutdown device / belt tensioner
- 20 - 21 - 39 -
Preparatory work:
Engines with enclosure
- Take off the cover for the air guide housing
and front impeller.
Engines without enclosure
- Take off belt guard, if fitted.
Removing:
- Press back the tensioning roller and attach
the locking device - 39 - (Fig. 149).
- Take out screws (150/3) with spring was-
hers and remove the drive pulley
(150/4)(the drive pulley is not fitted from
year of manufacture 1985 onwards). 149
- Pull the belt pulley (150/5) out of its cente-
ring mount and take it off together with the
Poly-V belt.
- Detach the oil line (150/1) and remove the
3 machine screws (150/2) with spring was-
hers.
- Detach the mount (150/7) at the cooling
fan, noting the installed shims.
- Take off the engine shutdown device
(150/6).
150
L / M . . 01.97
3
Dismantling the engine shutdown de-
vice:
(from engine serial numbers L 30.15,
2 L 40.12, 3/4 L 40.11).
- Remove the locking device.
Warning:
The piston with tensioning roller are spring-
loaded; release the spring loading gradually.
- Take out circlip (152/1).
- Unscrew the nut (151/1) and take out the
machine screw (151/2) with sleeve (151/3)
and washers (151/4) and (151/5), at the
same time forcing the tensioning roller 151
(151/6) back slightly against its spring loa-
ding.
- Carefully release the spring loading com-
pletely 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 remo-
ve the tensioning roller. 31
- Take off the Nilos rings (151/8). Drive the
ball bearings (151/9) out towards the outsi- 174
de 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 score-
or wear-marks. If damaged, renew the bus-
hings or the piston.
To renew the bushings, use special tools -
20 - 21 - and press the bushings in 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.
152
L / M . . 01.97
3
Assembling:
- Assemble by following the dismantling pro-
cedure in the opposite order.
- Make sure that the Poly-V belt is fitted cor-
rectly.
Assembly instructions:
- Insert restrictor screw (153/1) with sealant
D.
- Pack the Nilos rings (151/8) with anti-fricti-
on bearing grease when assembling.
Note for older versions of L 30 / L 40 engi-

nes:
- The circlip (152/1), support washer (152/2)
and quad rings (152/4) and (152/5) have
been installed since 1980.
- A ball pressure-relief valve was installed in- 153
stead of the restrictor screw (153/1) until
about early 1982.
- A modified tensioning roller mount is used
from the L 30.15 / 2 L 40.12, 3/4 L 40.11
onwards.
L / M . . 01.97
3
M 22.00 Air cleaner
– Assembling:
- Follow the instructions in the reverse or-
Dismantling:
der.
L-engines
- Take off the enclosure hood.
- Remove dirt adhering in the air cleaner
housing area.
- Loosen screws (175/1) only sufficiently to
permit the complete air cleaner housing to
be raised. 1
- Cover the opening in the intake pipe to pre-
vent dirt or other foreign bodies from ente-
ring.
- Open the air cleaner housing and take out
the filter element (176/3).
On three-cylinder engines, the cover
(176/2) is also held with a clip (176/7). 175
M-engines
- Release the clips (177/1) and take off the
air cleaner housing cover (177/2)
- Remove dirt adhering in the region of the
air cleaner housing.
- Slacken off screws (177/3) only enough to
permit the cover (177/4) with filter element
(177/7) to be raised.
- Cover the opening in the suction pipe to
prevent dirt and other foreign bodies from
entering.
176
Checking / repairs:
- Check the sealing faces for signs of dama-
ge. 1 2
- Clean the filter housing and the cover.
Spacer ,,5“ is connected by an elastic sleeve 3
,,6“ with the retaining screw, so that it cannot
fall into the intake pipe during maintenance 3 4
work.
6
- If the spacer is loose, renew bushing ,,6“. 7 5
5
L3/58
177
L / M . . 01.97
3
M 31.00 Crankcase breather
General:
The crankcase breather operates by way of
a diaphragm valve in the intake pipe.
During maintenance or repair work, in par-
ticular if the engine’s oil consumption is high
or it is producing too much blue exhaust
smoke, you are recommended to check the
condition of the diaphragm. 5
Dismantling:
- Pull housing 1 with cap 2 and diaphragm
3 out of the intake manifold and hose 4
(Fig. 178). 1
- Pull cap 2 out of housing 1 and remove dia-
phragm 3.
Checking / repairs
- Examine the diaphragm for cracks and re- 3 4
new if necessary. 2
- Renew O-rings 5.
Assembling:
- Proceed in the opposite order to that de-
scribed above.
178
L / M . . 01.97
3
M 32.00 Speed control
M 32.10 Engines with PFR 1K 80 injection pump
Preparatory work:
- Detach the enclosure hood.
- Take off the speed control lever and the
side panel; see M 35.00.
- Renew the oil cleaner.
- On two-cylinder engines, unscrew and re-
move the oil filler pipe; see M 12.00.
Dismantling:
- Remove machine screws (154/1). 154
- Turn the speed control shaft counter-clock-
wise to the ,,Stop“ position and pull the go-
vernor rod towards the flywheel end;
see Fig. 155.
- As shown in Fig. (155/1), move the gover-
nor lever over to the timing side and pull it
out downwards.
Dismantling the speed control:

- Pull out the cotter pin or locking collet
(156/1) and push out the bolt (156/2). 155
- 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), remo-
ve circlip (156/14) with spacing washer
(156/15) and pull out shaft (156/9).
156
L / M . . 01.97
3
Checking / repairs:
- Check ball bearing at governor lever for
wear.
- Check governor lever, pin for speed con-
trol, fork, adjusting shaft and housing for
score-marks; renew parts if damaged.
Assembling:
- Push in the shaft and install the spacing
washer, circlip, governor shaft stop,
shim(s), support disc, circlip and ten-
sioning plate.
Push on the fork (157/3) and drive the lock-
ing collet 157/4) in flush with the fork; see 157
Fig. 157.
- Push on the sleeve (158/1) and torsion
spring (158/2), then drive in the locking
collet (157/4) flush with the fork; see Fig.
158. Preload torsion spring (158/2) by a
quarter-turn clockwise, then connect to the
locking collet.
- Further assembly is in the reverse order to
that described for dismantling; use a new
gasket.
- Apply sealant D to screws (154/1) when in-
serting.
158
L / M . . 01.97
3
M 32.00 Speed control
M 32.20 Engines with PFR 1K 90 injection pump
Dismantling:
- Remove machine screws (154/1).
- Turn the speed control shaft anti-clockwise
to the ,,Stop“ position and pull the 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) un-
der governor rod (179/3).
- Carefully pull the speed control mount out 154
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 179
wear.
- Check governor lever, speed control pin,
fork, control shaft and housing for score
marks and renew all damaged parts.
180
L / M . . 01.97
3
Assembling:
- Drive in locking collet (181/1) until it pro-
jects by 10.5 mm.
- Insert spring (181/2) into fork (181/3) and
push on to control shaft.
- Drive locking collet (181/4) in flush with the
fork and connect the spring to it, using a
suitable tool.
- Continue installation by following the remo-
val 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 in-
stalled again.
If the governor lever or the conplete speed
control is renewed, note that torque equali-
sation may have been activated at the origi-
nal governor lever.
In case of doubt, contact your nearest HATZ
service point.
L / M . . 01.97
3
M 35.00 Capsule
Preparatory work:
- Remove the engine.
Note:
It is normally only necessary to remove the
engine from the equipment in which it is
being used in order to dismantle the capsule
if the air guide housing or rear panel have to
be taken off.
- Remove exhaust capsule; see A 03.00.
Dismantling:
- Take off the hood (159/1), speed control le-
ver (159/2), side panel (159/3) and cover
plate (159/4).
159
- Detach the air outlet shaft (160/1) and co-

ver plate (160/2).
Note for 4 L 40 C:
Take out the cooling air guide lining ele-
ments.
- Take off the cross-member above the in-

jectors and raise the engine slightly at 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 ba-
seplate should be used to support the engi-
ne.
160
L / M . . 01.97
3
- Unscrew the earth (ground) strap and the
+ line from the rear panel of the enclosure.
- Take off the rear panel with intake duct;
see Fig. 161.
161
- Unscrew the cover from the air guide hou-

sing (162/1).
- Take out the screws holding the fan impel-
ler (162/2) and remove the impeller.
- Take off the air guide housing; see Fig.
163.
Checking the parts:

- Examine the various sections of the enclo-
sure for damage.
- Renew damaged or incomplete sealing
strips.
162
Assembling:
- Assemble the enclosure by following the
dismantling instructions in the reverse or-
der as appropriate.
Note:
Make sure that all enclosure sections are ca-
refully installed and that all sealing strips are
seated correctly. Unless the enclosure is
completely sealed, neither the potential level
of noise reduction nor adequate cooling can
be ensured.
163
L / M . . 01.97
3
Bestellu
Order fo
Comma
Pedido d
Ordine p
1 Bestelle
2 TYP
MOTOR
MIN -1
3 Ersatzteilli
4 St ck / Qt
5 Versanda
Post / Sur
Express /
6 Versanda
Bestellun
- die n ch
- your ne
- votre st
- al servic
- al piø vi
4. Tables
L / M . . 01.97 4
Tightening torques for threaded connections
General requirements in Nm:
Nm ÷ 9.81(10) = kpm
Nm ÷ 1.3558 = lb.ft
Strength category
Thread
5.8 8.8 10.9 12.9
M 4 1.7 2.8 3.9 4.7
M 5 3.4 5.5 7.8 9.3
M 6 6.0 9.5 13 16
M 8 14 23 33 39
M 10 29 46 65 78
M 12 50 80 110 140
M 14 80 130 180 220
M 16 120 190 270 330
M 18 170 270 380 450
M 20 240 380 530 640
M 22 320 510 720 860
4 L / M . . 01.97
Tightening torques in Nm
L 31. M 31
Engine L 30 L 40. M 40
L 41. M 41
Shouldered nuts on stud bolts (tierods) for cylinder head
50 65
(Coat the tierod thread and washer contact face in the oil cavity with sealant D)
Big end bolts: M 10 x 1 (8 mm Allen screw) 60 60

M 11 x 1 (10 mm Allen screw) – 115
Machine screws for counterweights 65 65
Machine screws for end cover, flywheel end
10 10
(Coat thread with sealant D)
Hex nuts for securing injectors 15 15

Pressure valve at injection pump 35 35
85 85
Collar nut for injector nozzle
L41. M41 40-50
Machine screws at balancing weight bearing journals (4-cyl.) 30 30
Machine screws at drive gearwheel for balancing weights (4-cyl.)
75 75
Hex nut for attaching spring bridge (governor) 25 25

Machine screws M 12 x190 (crankcase halves) 90 90
Flywheel bolts 135 200
Machine screws for gearwheel on crankshaft 30 30
Machine screws, M 6. for securing cam tracks 14 14
(injection timer)
Hex bolts for connecting housing 140 140
Front engine feet support mount (Silent Pack) 130 130

Hex bolts for governor weight holder 25 25
Hex nut for cylinder head cover (pressure-cast version) – 10
– 6.5
Machine screws holding solenoid valve to engine monitoring block
L / M . . 01.97 4
Repair data
Cylinder head L 41 L 31. M 31

L 30 H .L 30
M 41 L 40. M 40
Gap mm 0.85-0.95 1.0 - 1.1 1.0 - 1.5
Gasket at cylinder head mm 0.7 - 0.8 - 0.9 - 1.0 - 1.1 - 1.2 1.2
1)
Shim washers mm – 0.10 - 0.20
Valve clearance, cold 2)

mm 0.10 0.40
(20±10°C)
-0.015
Valve stem ∅ mm 8.96
Wear limit ∅ mm 8.85
Inlet valve head ∅ mm 43.1-0.3 40.1-0.3

Exhaust valve head ∅ mm 39.1-0.3 35.1-0.3
Recess of valve head max. mm 0.15 1.70

min. mm 0.00 0.85
+0.046
outer ∅ mm 15 +0.038
Valve guide +0.009

inner ∅ mm 9H6 0
Wear limit inner ∅ mm 9.05

+0.006
Bore in cylinder head ∅ mm 15 -0.012
Pressing-in force N 1000
Valve guide projection mm 20.5 23.5 (l=70.5)

20.5 14.5
20.5 (l=67.5)
Valve seat angle 45°
1) As required, between cylinder and crankcase

2) If steel pushrods are used: 0.20 mm
4 L / M . . 01.97
Repair data
Cylinder head L 31. M 31

L 40. M 40 L 30 H .L30
L 41. M 41
Length of inner
valve spring, off-load mm 45.5
Wear limit mm 44.0
Length of outer
valve spring, off-load mm 58.0
Wear limit mm 56.5

-0.020
Rocker shaft ∅ mm 19 f 6 -0.033

+0.021
Bore in rocker ∅ mm 21 H 7 0
+0.046
Rocker bushing inner ∅ mm 19 -0.012
Wear limit inner ∅ mm 19.20
Radius at rocker mm 8
(no flats must have formed)
Rocker endplay mm 0.1 - 0.2

(insert shims only on the
circlip side)
L / M . . 01.97 4
Repair data
Camshafts (injection pump drive and valve gear)
Camshaft bearing journal diameters
-0.060
Timing-gear side and cen- mm 54 e 6 -0.079
tre
Wear limit mm 53.85

+0.021
Flywheel end mm 20 m 6 +0.008
(ball bearing seat)
Internal diameter of bearing bore in crankcase
+0.030 +0.058
Timing end mm 54 H 7 0
(bushing for. 54 -0.002
camshaft)
Wear limit mm 54.10

+0.030
Centre mm 54 H 7 0
Wear limit mm 54.10

-0.007
Flywheel end mm 47 K 7 -0.018
(ball bearing seat)
+0.018
Bore for tappet mm 16 H 7 0
in crankcase
Wear limit mm 16.05

-0.016
Tappet shaft ∅ mm 16 f 7 -0.034
Wear limit mm 15.9
Camshaft endplay mm 0.1
4 L / M . . 01.97
Repair data
Balancing weights
Bearing point diameters – two– and three–cylinder engines

0
Balancing weight shaft mm 28 h 5 -0.009
Endplay – two–cylinder engines mm 0.15 - 0.6

–three-cylinder engines mm 0.15 - 0.7
Wear in the needle roller ∅ mm down to 27.97

bearing area
Bearing point diameters – four-cylinder engines

-0.080
Bearing journals for mm 44 d 6 -0.096
balancing weights
+0.018
Bearing bushing for balancing mm 44 +0.083
weights (pressed-in)
Endplay mm 0.15 - 0.4
L / M . . 01.97 4
Repair data
.L 30 / H .L30 .L 31 / .M 31 .L 41 / .M 41
.L 40 / .M 40
Conrod
+0.016 +0.016
Bore for piston pin (small end) ∅ mm 35 H 6 0
39 H 6 0
bushing +0.019 +0.019
Big end bore ∅ mm 63 H 6 0
67 H 6 0
+0.085 +0.085
Piston pin bushing external ∅ mm 35 +0.045
39 +0.045
+0.075 +0.080
pressed-in internal ∅ mm 32 +0.030
36 +0.035
Wear limit internal 32.30 36.30

∅ mm
Max. misalignment* 0.08 0.08
mm
Cylinder
Bore mm 95 +0.01 102 +0.01

Wear limit mm 95.15 102.15
Oversize mm +1.0 +0.5 / +1.0**
Roughness Ra 0.9 - 1.3 µ (1µ= 1/1000 mm)
Piston
Normal ∅ mm 94.94 101.92 101.90

Oversize mm +1.0 +0.5 / +1.0**
Play max. mm 0.07 0.09 0.11
Play min. mm 0.06 0.08 0.10
+0.009 +0.010
Piston pin bore ∅ mm 32 +0.004
36 +0.004

0 0
Piston pin 32 36 -0.006
∅ mm -0.006
Wear limit 31.95 35.95

mm
Piston ring endplay max. 0.2 0.2
mm
4 L / M . . 01.97
Repair data
Piston rings
.L30. H.L 30
End gap mm:
Ring groove No. Designation Dimensions 1)
normal max.
Standard 95 x 87 x 3
I Trapezoidal 0.40 - 0.65 1.0
Oversize 96 x 87.9 x 3
Standard Cutaway 95 x 87 x 3
II 0.40 - 0.65 2.0
Oversize micro-chamfer 96 x 87.9 x 3
Standard 95 x 87 x 5
III D-ring 0.30 - 0.60 2.0
Oversize 96 x 87.9 x 5
Piston rings
.L 31, .M 31, .L 40, .M 40, .L 41, .M 41,
End gap mm:
Ring groove No. Designation Dimensions 1)
normal max.
Standard 102 x 93.4 x 3
I Trapezoidal 102.5 x 93.9 x 3 0.40 - 0.65 1.2
Oversize
103 x 94.4 x 3 *
Standard 102 x 93.4 x 2.5
Cutaway
II 102.5 x 93.9 x 2.5 0.40 - 0.65 2.5
Oversize micro-chamfer
103 x 94.4 x 2.5 *
Standard 102 x 93.4 x 4
III D-ring 102.5 x 93.9 x 4 0.30 - 0.60 2.5
Oversize
103 x 94.4 x 4 *
1)These are maximum limit values which

can still be accepted without risk of engine
power output, oil consumption and exhaust
emissions being affected.
The piston rings should be renewed 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 4
Repair data
Crankshaft .L 31 / .M 31
.L 30 / H .L 30 .L 40 / .M 40
.L 41 / .M 41
0 0
Crankpins ∅ mm 60 h 6 -0.019
64 h 6 -0.019
Out-of-roundness max. mm 0.05

Conicity max. mm 0.003
+0.062 +0.062
Width mm 32 H 9 0
32 H 9 0
Radius mm 3.5 4.0 +0.3

0
Centre bearing journal ∅ mm 72 h 6 -0.019

Width mm 32 +0.3
Radius mm 3.5 -0.2 3.75 -0.2

0
Main bearing journal, ∅ mm 72 h 6 -0.019
timing end
Width mm 26.5 -0.2
Radius mm 3.5 -0.2
0
Main bearing journal. ∅ mm 72 h 6 -0.019
flywheel end
Width mm 27 ±0.2 32 +0.3

Radius mm 3.5 -0.2 3.75 -0.2
0 0
Contact face for shaft ∅ mm 70 h 11 -0.190
80 h 11 -0.190
sealing ring, flywheel side
4 L / M . . 01.97
Repair data
Crankshaft .L 31 / .M 31
.L 30 / H .L 30 .L 40 / .M 40
.L 41 / .M 41
Regrinding during repairs mm 0.5

Hardness Rc 50 - 55
Hardening depth mm 2.5
Big end bearing,

internal (installed) +0.083 +0.063
Normal ∅ mm 60 +0.040
64 +0.040
Wear limit ∅ mm 60.20 64.20

+0.083 +0.083
Undersize ∅ mm 59.5 +0.040
63.5 +0.040
Wear limit ∅ mm 59.7 63.7
Wall thickness, normal mm 1.468 - 1.480

Undersize mm 1.718 - 1.730
Main bearing, internal

(installed) +0.099
Normal ∅ mm 72 +0.056

+0.099
Undersize ∅ mm 71.5 +0.056

Wall thickness, normal mm 2.960 - 2.972
Undersize mm 3.210 - 3.222
Crankshaft endplay mm 0.15 - 0.65
Max. permissible bearing

play after wear mm 0.3
L / M . . 01.97 4
Fuel injection equipment
Up to engine serial numbers: 2 L 40.16. 3 - 4 L 40.15. .M 40.12. L 30 and H.L 30
Start of
Engine type Injection pump HATZ Ident No.
delivery
PFR 1 K 80 A 442/2 1)
2 - 4 L 30 PFR 1 K 80 A 442/11 1) 17 - 18°
H .L 30 before TDC
PFR 1 K 80 A 467 1) 2) 501 407 00
PFR 1 K 80 A 467 3) 501 407 10
2 - 4 L 40 PFR 1 K 80 A 477 2) 502 368 00 17 - 18°
2 - 4 M 40 PFR 1 K 80 A 477 3) 502 368 10 before TDC
1) Interchangeable
2) With governor-rod stop at pump
3) 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
Engine type Injection pump HATZ Ident No.
delivery
L 31. M 31 15°
PFR 1 K 90 A 498 502 630 00
L 40. M 40 before TDC
10°
L 41. M 41 PFR 1 K 90 A 546 504 442 01
before TDC
Injectors
Injector nozzle Spray

Engine type HATZ-Ident-No.
Bosch HATZ pressure
L 30. H.L 30 +8
L 31. M 31 401 209 01 DLLA 160 S 908 501 413 01 250 bar
L 40. M 40
+12
L 41. M 41 504 440 00 DSLA 150 P 645 504 441 00 230 bar
4 L / M . . 01.97
Governors
L 30. H .L30
Governor spring Governor weight
Speed Application
Ident-No. Wire ∅ mm Ident-No.
≤ 2300 Normal 036 012 01 3.0

> 2300 operation 035 744 01 3.2
1500 * 036 014 01 2.5 035 729 00
Generator
1800 * drive 036 013 01 2.6
3000 035 744 01 3.2
* When driving a generator at 1500 and 1800 rpm governor weights with Ident No.
036 349 00 were used from 1979 to 1982. They are identifiable by a ,,G“ stamped
on the end or a white spot.
If needed, renew these governor weights as a complete set, since governor weights
with Ident-No. 035 729 00 are now installed for all running-speed ranges.
L 40. M 40 with injection pumps PFR 1K 80A 477

Speed Application
≤ 2300 Normal 036 012 01 3.0

> 2300 operation 035 744 01 3.2
1500 037 739 00 2.5 * 035 729 00
Generator
1800 drive 036 013 01 2.6
3000 035 744 01 3.2
* Identifiction: windings are ground away slightly at circumference.
L 31. M 31. L 40. M 40 with injection pump PFR 1K 90A 498 and L 41 and M 41
Speed Application
≤ 2300 Normal 036 012 01 3.0

> 2300 operation 035 744 01 3.2
1500 038 670 00 2.3 * 035 729 00
1500 Generator 036 014 01 2.5
drive
1800 036 013 01 2.6
3000 035 744 01 3.2
* With this governor spring the spacing ring, Ident No. 037 729 00, is deleted
(Fig. 48a/50)
L / M . . 01.97 4
Lubricating oil content and dipstick
Oil content Dipstick

Engine type Oil sump
l marking
Two-cylinder
engines with 7.5 C
.L.. C / Z without 4.5 A
with 8.5 C
.L.. S. M..
without 5.5 A
Three-cylinder
engines with 10.5 D
.L.. C / Z without 8.0 A
with 11.0 D
.L.. S. M..
without 8.5 A
Four-cylinder
engines
.L.. C / Z with 13 D
.L.. S. M.. with 14 D
Note:
The lubricating oil contents stated here are to be understood as approximate; they 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.
4 L / M . . 01.97
Key to circuit diagrams (DIN 40719)
Key Designation of electrical component

A1 Instrument box
A2 Instrument panel
A3 Automatic start-stop
A4 Starter protection module
B1 Temperature sensor
B2 Speed pulse transmitter
B3 Oil pressure sensor
B4 Signal horn
C1 Condenser
E1 Fuel filter heater
F1 Fuse
G1 Battery
G2 Alternator
G3 Flywheel generator
H1 Generator telltale light
H2 Oil pressure warning light
H3 Engine overheat warning light
H4 Air cleaner telltale light (maintenance switch)
H5 Belt break warning light
H6 Pre-heat monitor telltale light
H7 Fan monitor warning light
H8 Remote display: engine running
K1 Control relay 1 for start / start repeat interlock
K2 Control relay 2 for pre-heating
K3 Control relay 3 for speed control
K4 Engine protection relay
K5 Delaying relay
K6 Start inhibit relay
K7 Timer (impulse) relay
K8 Power relay
M1 Starter motor
MG Starter generator
N1 Voltage regulator for starter generator
N2 Voltage regulator for flywheel generator
N3 Voltage regulator for alternator (unless integrated)
N4 Pulse transmitter (additional item for synchro-regulator)
L / M . . 01.97 4
Key to circuit diagrams (DIN 40719)
Key Designation of electrical component

P1 Operating hours counter
P2 Revolution counter
P3 Pressure gauge
R1 Pre-heat plug
R2 Heating flange
R3 Line resistor for pre-heat system
R4 Resistor
R5 Line resistor with thermo-times switch
S1 Pre-heat start switch (5-position)
S2 Master switch
S3 Pre-heat/start switch (3-position)
S4 Start-stop-switch
S5 Swich for speed control
S6 Engine temperature switch
S7 Oil pressure switch
S8 Pressure switch for air-cleaner
S9 Fan monitoring switch
S 10 Pre-heat temperature switch
S 11 Remote-start switch
S 12 Remote stop switch
T1 Transducer for speed measurement
V1 Decoupling diode
V2 Freewheeling diode
V3 Zener diode
V4 Suppressor diode
W1 Earth (ground), negative return line
W2 Screened line at generator
X1 Terminal strip at instrument box
X2 Flat-pin junction box
X3 Plug at emergency stop switch
X4 Socket at emergency stop switch
X5 Terminal block in control box / terminal box
Y1 Solenoid for speed control
Y2 Solenoid for engine shutdown
Y3 Servo (valve) solenoid for engine shutdown
Y4 Fuel shut-off valve
Y5 High-pressure shut-down valve
Z1 Suppressor choke
Z2 Suppressor capacitor
4 L / M . . 01.97
HATZ - Wiring identification
Terminal Designation
0 Earth (ground)
1 Alternator B+
2 With alternator: D+
With flywheel generator: terminal L at voltage regulator
3 Starter terminal 50
4 Oil pressure switch
5 Temperature switch on cylinder head
6 Pre-heat plug I
7 Engine shut-down solenoid
8 Pre-heat II
9 Start-stop input
10 Positive terminal for DC fine speed control motor
11 Negative terminal for DC fine speed control motor
12 Oil pressure sensor
13 * * * Reserved for special purpose * * *
14 Speed control solenoid hold-on winding
15 * * * Reserved for special purpose * * *
16 Decompression solenoid
17 Air cleaner maintenance switch
18 Engine shut-down solenoid (energizing winding)
19 Temperature sensor on cylinder head
20 Oil temperature switch
21 Fan monitoring switch
22 Terminal W for engine speed measurement
23 Starter 30 (if ammeter is connected)
24 Terminal C if voltage regulator is on flywheel generator
25 Oil temperature sensor
26 Terminal 50f at starter protection module
27 * * * Reserved * * *
28 Speed control solenoid (energizing winding)
29 * * * Reserved * * *
L / M . . 01.97 4
4
Circuit diagram 12 V - system with fault display
L / M . . 01.97
1 2 3 4 5 6
30
15
50
19
S1 30 86 17
58 50a 15 19 17 V1 K2 15
P0123 W-1
87 85
H1 H4 H2 H3 S5
P, 0, 1 86 K3 30
30 V2 H6 H6 P2 n
85 87
P1 h
W-6 F1 8A
V2
4 L / M 31,40,41 only
X1 1 22 3 X1 2 17 4 5 X1 7 X1 0 6 8 14
Instrument box
Engine
R1 R1
D+ B+ 30 50 S8 S7 S6 3 7
AW HW 7
G W Pu P t° Y3 Y1
M 0 0
U
G2 G1 M1
31
Power supply Starting device Monitoring + display Engine shut-down Pre-heating Optiones
Charging device (Hour-run meter, speed adjustment)
Circuit diagram 12 V - system with fault display and starter protection module
1 2 3 4 5 6
A4
30 86
58 50a 15 19 17
87 85
P, 0, 1 86 30
30 n
85 87
h
1 22 3
4 L / M 31,40,41 only
2 17 4 5 7 0 6 8 14
Instrument box
Engine
D+ B+ 30 50
W u
L / M . . 01.97
4
4
Circuit diagram 12 V - system with automat. shut down and starter protection module
L / M . . 01.97
1 2 3 4 5 6
A4
30 86
58 50a 15 19 17
87 85
P, 0, 1 50 86 30
15
30 n
SE 31 87 85 87
h
4 L / M 31,40,41 only
1 22 3 2 17 4 5 7 0 6 8 14
Instrument box
Engine
D+ B+ 30 50
W u
Circuit diagram 12 V - system with automatic shut-down and time relay
1 2 3 4 5 6
30 86
58 50a 15 19 17
30 87 85
85
P, 0, 1 50 15 30 86 30
15
30 86 87a 87 n
SE 31 87 85 87
50 31 87 h
1 22 3 2 17 4 5 18 7 0 6 8 14 4 L / M 31,40,41 only
Instrument box
Engine
D+ B+ 30 50
W u
L / M . . 01.97
4
4
Circuit diagram 12 V - automatic start/stop with repeat start interlock and time relay
L / M . . 01.97
1 2 3 4 5 6
30 86
58 50a 15 19 17 86 30 15 30
87 85
85 31 87
P, 0, 1 SE 86 30
87 15
30
15 30
n
50 31 87 85 87
h
50 31 87
30 31 61
4 L / M 31,40,41 only
1 22 3 2 17 4 5 18 7 0 6 8 14
87 50e Instrument box
Engine
D+ B+ 30 50
W u
Circuit diagram 24 V - system with fault display
1 2 3 4 5 6
58 50a 15 19 17
P, 0, 1 86 30
30 n
85 87
h
1 22 3 2 17 4 5 7 0 6 8 14
4 L / M 31,40,41 only
Instrument box
Engine
D+ B+ 30 50
W u
L / M . . 01.97
4
4
Circuit diagram 24 V - system with fault display and starter protection module
L / M . . 01.97
1 2 3 4 5 6
A4
58 50a 15 19 17
P, 0, 1 86 30
30 n
85 87
h
4 L / M 31,40,41 only
1 22 3 2 17 4 5 7 0 6 8 14
Instrument box
Engine
D+ B+ 30 50
W u
Circuit diagram 24 V - system with automatic shut-down and starter protection module
1 2 3 4 5 6
A4
58 50a 15 19 17
P, 0, 1 50 86 30
15
30 n
SE 31 87 85 87
h
1 22 3
4 L / M 31,40,41 only
2 17 4 5 7 0 6 8 14
Instrument box
Engine
D+ B+ 30 50
W u
L / M . . 01.97
4
4
Circuit diagram 24 V - system with automatic shut-down and time relay
L / M . . 01.97
1 2 3 4 5 6
58 50a 15 19 17
85 30
P, 0, 1 50 15 30 86 30
15
30 86 87a 87 n
SE 31 87 85 87
50 31 87 h
4 L / M 31,40,41 only
1 22 3 2 17 4 5 18 7 0 6 8 14
Instrument box
Engine
D+ B+ 30 50
W u
Circuit diagram 24 V - automatic start/stop with repeat start interlock and time relay
1 2 3 4 5 6
58 50a 15 19 17 86 30 15 30
85 31 87
P, 0, 1 SE 86 30
87 15
30
15 30
n
50 31 87 85 87
h
50 31 87
30 31 61
4 L / M 31,40,41 only
1 22 3 2 17 4 5 18 7 0 6 8 14
87 50e Instrument box
Engine
D+ B+ 30 50
W u
L / M . . 01.97
4
Trouble-shooting table for electrical system
Trouble-shooting at instrument box
Malfunction Cause Remedy

Starter remains enga- Pre-heat/starter switch sticks in Set pre-heat/starter immediately
ged although pre- position 3 after starting and does to 0 by force; if this is not
heat/starter switch not return automatically to possible, disconnect the battery
was released. position I. at once.
(If the starter remains engaged
for more than 2 to 3 minutes, it
will burn out.)
Renew the pre-heat/starter switch.
Alternator telltale Bulb has blown or contacts are Insert a new bulb, clean the
light does not come corroded. contacts.
on when engine is Battery is flat. Recharge the battery.
stopped and pre-heat/
Battery is defective (internal Renew the battery.
starter switch is on.
short-circuits or sulphatised).
Defective pre-heat/starter switch, Eliminate contact resistance,
poor connections, defective renew wiring, tighten loose
wiring, contact resistance in terminals, if necessary renew pre-
charging current circuit or line to heat/starter switch.
generator telltale light.
Defective voltage regulator. Renew 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. Renew carbon brushes.
Oxide desposit on sliprings, Have generator repaired.
exciter winding is interrupted.
Generator telltale V-belt loose at generator. Correct V-belt tension.
light flickers.
Generator telltale Poor earth (ground) connection Make a clean earth connection in
light continues to in instrument box. the instrument box.
glow, after starting Wiring error, e.g. generator Check the line from the generator
engine. telltale light leads to oil pressure telltale light to the generator and
switch. correct the wiring if necessary.
4 L / M . . 01.97
Trouble-shooting at the battery
Malfunction Indication Cause Remedy

Battery not Terminal voltage Poor connections, open Eliminate the open
recharged, drops even a short circuit or contact circuit, clean the
recharged too time after recharging resistance in charging terminals, tighten
little or goes to 7 V despite a 12 V circuit, short-circuit in terminals if slack.
flat rapidly. nominal voltage (or line.
14 V if nominal Battery defective, internal Renew battery.
voltage is 24 V). short-circuit.
Capacity of battery has Recharge battery at low
dropped severely, current (app. 1/40 of
because it was heavily Nominal capacity in
discharged for a lengthy Amps) for about 50
period (greyish-white cell hours. (This is only
plates = ,,sulphatised“). possible if sulphate
coating is not yet too
stron.)
Otherwise:
renew the battery.
Battery poles connected Have generator repaired.
up wrongly, destroying
one or more diodes in
the generator.
Charge current too weak Recharge the battery.
(esp. in winter).
Battery capacity is too Install a smaller battery
large. or a larger generator.
Defective voltage Renew the voltage
regulator (e.g. regulator.
overheated/overloaded).
Loose V-belt at generator. Correct V-belt tension.
L / M . . 01.97 4

Corroded termi- Inadequate current Sulphuric acid attacs Wash down terminals with
nal clips. flow, white salt metals (except lead). hot soda lye (but this
deposits. must not enter the
battery!), rinse with cold
water and apply acid-
resistant grease.
Battery is Voltage at terminals Charging voltage too Check voltage regulator,
overcharged. is always above 16.5 high. renew if necessary.
V with 12 V nominal Capacity of chosen Install a battery of
voltage (or above battery is too small. larger capacity. As a
33 V with 24 V temporary measure,
nominal votage),
discharge the battery at
specific gravity of
intervals, e.g. by
acid is above 1.285
kg/l so that the switching on an
battery boils. 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. Siphon off excess acid.
the cell plugs.
Acid level is to Acid level less than Overloading or natural Add distilled water or
low 10 mm (0.4 in) below water loss by demineralised water.
top of cell plates. evaporation
(particularly in
summer).
4 L / M . . 01.97

Battery fails Battery was discharged Check ratings of battery and
prematurely. too often and too generator, if necessary fit a
serverely. special ,,Z“ or ,,HD“ battery.
Battery becomes too Install it at a more favourable
warm. point.
Excessive vibration. Install battery at a more
favourable point or use an ,,Rf“
battery (shakeproof)
Battery is discharging Charge the battery at a small
sulphates. current level (app. 1/40 of its
norminal capacity in Amps) for
about 50 hours.
Failing this, renew the battery.
Battery acid is Renew the battery.
contaminated.
Too little po- Voltage drops Run the battery down. Recharge battery with a
wer from severely when suitable charger.
battery. load is applied. Voltage regulator is Renew voltage regulator on
defective, so that generator.
charging voltage is too
low.
Connecting terminals Clean the terminal clips and
loose or oxidised. apply acid-proof grease to
them, then retighten the
terminal clips.
Battery capacity is too Install a larger battery and if
small (too many necessary a larger generator.
consumers).
Battery is going flat Renew the battery.
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 4

Rate of charge Terminal voltage Fault in generator, Repair or renew
never soon drops to 7 V voltage regulator or generator and voltage
adequate. after recharging wiring connections. regulater. Connect wiring
(12 V nominal firmly.
voltage) or to 14 V V-belt too loose. Correct tension or renew
(24 V nominal V-belt.
voltage).
To many consumers Install battery and
connected or generator generator with similar
is too small. ratings.
4 L / M . . 01.97
Trouble-shooting at the starting device

Starter motor Generator telltale Poor connections (loose Check battery lead and
does not turn light does not or corroded), break in connections, clean battery
when pre- come on. cable or short to earth posts and terminals, make
heat/start (ground). sure connections are clean.
switch is ope- Battery flat or defective. Recharge or renew battery.
rated.
Telltale light grows Battery is flat. Recharge the battery.
slowly dimmer
when pre-heat/start
switch is operated.
Telltale light is on Line between terminal 50 Repair the break or if
brightly. and starter switch or necessary renew the
Bridge terminals 30 between terminal 30 and starter switch.
and 50 briefly at battery is interrupted or
the starter motor, starter switch is faulty.
the starter then Starter inhibit relay or Renew defective relay.
turns. delaying relay defective.
Telltale light burns Starter pre-engagement Renew the starter motor
brightly. Terminal winding has burned out. and ensure a good
30 is not connected connection between
to positive battery terminal 30 at the starter
pole. and the positive battery
post (main starter line).
Telltale light burns Worn or dirty contacts on Renew solenoid switch.
brightly, solenoid solenoid switch.
switch is energised,
when solenoid
switch is bridged,
starter motor turns.
L / M . . 01.97 4

Starter motor Lengthy Carbon brushes sticking. Renew brushes and brush
turns too slowly operating period holder guides.
or cannot turn without Carbon brushes worn. Renew carbon brushes.
the engine over. maintenance or
Poor spring pressure, Renew springs.
in tough
carbon brushes not
environmental
making contact.
condition.
Commutator is dirty. Clean the commutator.
Commutator is scored Recondition or renew starter
or burnt. motor.
Armature or field coils Recondition or renew starter
defective. motor.
Starter engages Lengthy Battery is flat. Recharge the battery.
and is energi- operating period Low current flow Clean battery terminals,
zed, but engine without because of loose or tighten connections.
does not turn or maintenance, corroded connections.
only turns jer- electrical system
Carbon brushes sticking. Renew carbon brushes and
kily. has been
brush holder guides.
neglected.
Carbon brushes worn. Renew carbon brushes.
Commutator dirty. Clean commutator.
Commutator scored or Recondition or renew the
burnt. starter motor.
Armature or field Recondition or renew the
windings defective. starter motor.
Starter pinion Engine does not Starter pinion or helical Renew starter pinion,
does not enga- turn, or turns thread dirty or damaged. recondition starter motor.
ge or disenga- jerkily. Flywheel gear ring Remachine or renew gear
ge. damaged. ring.
Solenoid switch Renew solenoid switch.
defective.
Return spring weak or Renew return spring.
broken.
4 L / M . . 01.97

Starter motor Noise of Starter relay defective. Switch off engine manually
continues to run rotation. at once (set speed control
after switch was lever to ,,stop“ and
released. disconnect battery).
Consequential damage:
electronic components
destroyed.
For example: diodes in
generator.
Check switches, relays and
generator, renew parts if
necessary.
Pre-heat/switch does not Set pre-heat/start switch to
return automatically from 0 immediately using force if
position 3 to position 1. necessary and renew it. If
this is not possible:
disconnect the battery
immediately.
Consequential damage:
diodes in generator
destroyed.
Warning !
Unless the above
measures are taken within
2-3 minutes, the starter
motor will burn out
(overheating)
Diode in shutdown Renew solenoid.
solenoid (lifting or servo
electromagnet) is
defective.
Engine does not Valve solenoid on Check operation of valve
start or starts re- monitoring block is not solenoid and renew if
luctantly, al- opening. necessary.
though the star- Pre-heat system is Check pre-heat circuit and
ter motor is tur- defective (only significant renew any defective parts.
ning strongly. at temperatures below -
10 to -15°C.)
L / M . . 01.97 4
Trouble-shooting at the pre-heat system
Indication Cause Remedy

Spiral indicator ele- Short to earth (ground) in a pre- Renew the pre-heat plug.
ment (pre-heat moni- heat plug, pre-heat element
tor) glows brightly al- (filament) is bent and shorting
most immediately. inside engine.
Broken pre-heat wires in a line Renew the line resistor.
resistor, winding shorted to an
earthed component.
Unterbrechung der Since the pre-heat monitor, pre- Use a test lamp or a voltmeter
Glühanlage (Glühüber- heat plug or heating flange (and (with the pre-heat system
wacher brennt nicht) also the second pre-heat plug or switched on) to check all the pre-
line resistor on 24 V systems) heat monitor connections.
are wired in series, the complete Renew defective parts.
pre-heat system is out of action
if a component fails.
4 L / M . . 01.97
Trouble-shooting at the alternator

Generator telltale light Line D+/61 has a short to earth Renew the line or repair the
does not go out as en- short to earth.
gine speed increases. Voltage regulator on generator is Renew voltage regulator.
defective.
Wiring connections interchanged Connect the wiring correctly.
at generator.
V-belt for generator is slipping or Correct V-belt tension or renew
broken. V-belt.
Defective rectifier on generator, Have generator repaired.
dirty sliprings, short-circuit in line
DF or rotor winding.
Generator telltale light Generator is not sufficiently Install a bulb of higher rating,
does not go out at low excited by telltale light. A 2 Watt e.g. 2 W -> 3 W.
engine operating speed bulb is normally used in the light. Warning: bulb ratin must not
(e.g. 1500 rpm) exceed 5 W (or pre-exciter
circuit will be destroyed)
Generator telltale light Rate of charge too low, brief Short-term remedy: recharge
glows only dimly when engine operating periods battery with a suitable charger.
engine is stopped and (particularly when a maintenance- Long-term remedy: use a
pre-heat/start switch is free, vibration-proof battery is battery with better charge
operated, battery not used). characteristic.
being charged, or char- Poor connections, open circuit, Repair the break, clean the
ging only at a low rate. contact resistance or short-circuit battery terminals, tighten loose
in charging circuit. clamps.
Battery is defective, internal short- Renew battery.
circuit.
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. Install a smaller battery or a
larger alternator.
Alternator is defective. Have alternator repaired.
Voltage regulator is defective. Renew voltage regulator.
Loose V-belt at alternator Correct V-belt tension.
L / M . . 01.97 4
Trouble-shooting at the alternator

When engine is Poor connections, contact Eliminate contact resistance,
stopped the gener- resistance in charge circuit or in clean terminals, tighten loose
ator telltale light the line to the generator telltale terminals.
burns brightly, but light.
when engine is Defective voltage regulator. Renew voltage regulator
running telltale
Defective alternator. Have alternator repaired.
light glows dimmer.
Generator telltale Generator telltale light bulb has Install a new bulb.
light does not come blown or contacts are corroded. Clean the contacts.
on when engine is Battery is flat. Recharge with a suitable charger.
stopped and pre-
Battery is defective (internal short- Renew the battery.
heat/start switch is
circuit or sulphate deposits).
turned on.
Defective pre-heat/start switch, Eliminate contact resistance,
poor contacts. renew wiring, tighten loose
Defective wiring line resistance in terminals, if necessary renew pre-
charging circuit or line to generator heat/ start switch.
telltale light.
Defective voltage regulator. Renew the voltage regulator.
Short-circuit in an alternator Disconnect charging line B+ (to
exciter or positive diode. prevent discharge at a standstill),
have alternator repaired.
Carbon brushes worn. Renew carbon brushes.
Corrosion deposits on sliprings, Have alternator repaired.
open circuit in exciter winding.
Generator telltale V-belt at alternator is too slack. Tension V-belt correctly.
light flickers.
4 L / M . . 01.97
Trouble-shooting at engine monitor and display

Sudden pressure drop Leak in oil circuit. Check lines and seals, renew if
in lubricating oil necessary.
circuit. Oil lost from damaged sump. Renew the oil sump.
Defective oil pump. Renew the oil pump.
Engine cannot be stop- Defective valve solenoid or fuel Examine parts and renew if
ped at valve solenoid shut-off valve. necessary.
or fuel shut-off valve. Defective diode between Check the circuit and renew the
generator telltale light and diode if necessary.
terminal 15 at pre-heat/start
switch, or diode by-passed.
Incorrect display, light Short to earth (ground) in wire or Check wiring and eliminate
does not come on al- switch. short to earth.
though a fault is pre- Defective switch. Renew switch.
sent.
No display, display Broken wire. Renew broken wire.
light does not come on Defective switch or relay. Renew defective components.
despite malfunction.
Defective bulb. Renew the bulb.
Engine protection relay: see ,,Instrument box“
L / M . . 01.97 4
Trouble-shooting at electromagnetic components

Electromagnet Defective electromagnet (e.g. Renew electromagnet.
does not switch winding burned out).
engine off or vary No power supply or open circuit. Check the circuit.
engine speed.
Defective switch or relay. Renew defective component.
Decoupling diode between Check the circuit and install or
generator telltale light and terminal renew decoupling diode as
15 is missing or defective (applies necessary.
only to shut-down solenoid with
alternator).
Malfunction or fai- Freewheel diode parallel to a Renew freewheel diode.
lure of other electri- solenoid is defective.
cal or electronic
components.
Starter motor does Defective diode in shut-down Renew solenoids.
not disengage. solenoid (lifting or servo solenoid).
4 L / M . . 01.97

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Workshop manual

3. Basic engine equipment

Use only genuine HATZ spare parts in repair work.

A = 502 230 01 Loctite Activator 500 ml

Service and flywheel side Starter and flywheel side

Service and flywheel side Service and governor side

Service and governor side Starter and flywheel side

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

Service side Governor and exhaust side

Costumer spec. list No. 1)

MOTOR / FABRIK NO. ABE / AUSF. Output in kW 2)

Type 2L30 H2L30 3L30 H3L30 4L30

Control side 30° 30° 25° 25°

Control side 30° 30° 25° 25°

Control side 30° 30° 25° 25°

No. Ident-No. Item Code

No. Ident-No. Item Code

A 01.40 Fuel delivery pump

- Remove the hood from the enclosure and 4

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

- Remove the machine screws (186/1) and

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

- Pull the upper and lower sections of the en-

Check the parts:

A 04.10 Crank handle

A 04.10 Crank handle

leaf spring 11 cannot escape.

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

The automatic decompressor has the follo-

0 = Operating position, with engine running

- Take off cover (94/20) with gasket (94/37). 93

Dismantling the automatic decompres-

Adjusting the automatic decompressor:

Adjustment is needed if: L3 / 43

Check dimension ,,B“:

A 04.70 Recoil starter

Detaching the recoil starter: (Fig. 190)

Assemble in the opposite order of work as

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

Operational check with start release de-

- Prime the fuel delivery pump with the lever

General instructions on the engine’s Checking operation of the alternator

When series production of Series L / M engi-

When replacing a MARCHAL alternator by a

When installing a VALEO voltage regulator,

A 07.10 Oil cooler (air-cooled engines)

Removing block-pattern oil cooler:

Checking parts: 197

A 07.11 Oil cooler (water-cooled engines)

A 11.10 Engine shutdown solenoid (up to serial numbers

A 11.70 Temperature-controlled starting fuel volume control

A 15.20 Adapter housing

A 30.20 Water pump (H.L 30)

A 30.40 Thermostat (H.L 30)

Checking operation of thermostat insert: 202

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

- Tighten the machine screws for the driver

M 01.20 Removing and installing balancing weights - 4 L

- Invert the lower part of the crankcase.

- Unscrew splash plate (9/1) and take out ba-

- Coat the bearing bushings (12/1) with

- Insert splash plate as shown in Fig. 14, in-