Workshop Manual: 2-4L30. H2-3L30. 2-4L31. 2-4L40. 2-4L41. 2-4M31. 2-4M40. 2-4M41

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
Downloaded from www.Manualslib.com manuals search engine

Contents
Introduction
1. General 2. Additional equipment

Illustrations of engine A 01.00 Fuel
Type plate data A 01.40 Delivery pump
Lubricating oil circuit with hand pump
Technical data A 03.00 Exhaust
Sealants and adhesives A 03.12 Detaching and attaching
Special tools and enclosure for silencer
Workshop equipment (muffler)
A 04.00 Mechanical starting
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 Connecting housing
A 30.00 Liquid cooling
A 30.20 Water pump
A 30.40 Thermostat

Contents
3. Basic engine equipment M 14.00 Fuel injection equipment

M 01.00 Crankshaft M 14.00 Injection pump, functional test
M 01.10 Balancing weights 2L / 3L M 14.10 with injection pump
M 01.20 Balancing weights, 4L PFR 1K 80
M 01.30 Cleaning crankcase, M 14.20 with injection pump
installing injector nozzles PFR 1K 90
M 02.00 Crankshaft M 14.30 Injector
M 04.00 Camshaft M 14.40 Injector nozzle
M 04.10 Camshaft for valve timing M 14.50 Adjusting work with
M 04.20 Camshaft for injection pump injection pump PFR 1K 80
M 04.30 Governor and injection timer M 14.60 Adjusting work with injection
M 05.00 Conrod pump PFR 1K 90
M 06.00 Piston and cylinder M 17.00 Flywheel
M 06.10 Air-cooled engines M 20.00 Engine shutdown device,
M 06.20 Water-cooled engines belt tensioner
M 07.00 Cylinder head M 22.00 Air cleaner
M 07.10 Air-cooled engines M 31.00 Crankcase breather
M 07.20 Cylinder head repairs M 32.00 Speed control
(air-cooled engines) M 32.10 with injection pump
M 07.30 Water-cooled engines PFR 1K 80
M 07.40 Cylinder head repairs M 32.20 with injection pump
(water-cooled engines) PFR 1K 90
M 10.00 Oil pump M 35.00 Enclosure
M 11.00 Timing case cover
M 12.00 Starting charge
M 12.10 with injection pump
PFR 1K 80 4. Tables
M 12.20 with injection pump Tightening torques
PFR 1K 90 Repair data
M 12.30 with injection pump Fuel injection equipment and
PFR 1K 90 adjusting values
from serial No. L/M31.12, Governors
M40.16, 2L40.19, 3-4L40.18 Lubricating oil contents and dipstick
and L/M41 Key to circuit diagrams
M 13.00 Fan HATZ wiring identification
Circuit diagrams
Trouble-shooting table for the
electrical system

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.

1. General
L / M . . 10.98 1
Engine illustrations
Service and flywheel side Starter and flywheel side
Engines: 2 - 4 L . . S / Z
Governor and exhaust side
1 Lub.-oil filling and dipstick
2 Speed control lever
3 Exhaust silencer
4 Oil drain plug
5 Lub.-oil filter
6 Engine cover
7 Side panel
8 Cooling fan with built-in alternator
9 Cooling fan drive belt
10 Hydraulic belt tensioner
11 Stop device
12 Governor housing
13 Cooling air duct for lub.-oil cooler
21 Cyclone-type pre-cleaner
22 Eye hook for transport, disappearing
max. load 500 kg
23 Access to fuel feed pump
24 Starter motor
25 Fuel feed line
26 Fuel return line
27 Belt pulley with 1/2“ internal square
for cranking engine
1 L / M . . 10.98
Operating and flywheel side Operating and governor side
Encapsulated design
1 Lub.-oil filling and dipstick Outgoing air and flywheel side
2 Speed control lever
4 Oil drain plug
5 Lub.-oil filter
6 Battery + terminal
7 Battery - terminal
8 Wiring harness
9 Type plate
10 Fuel feed line
11 Fuel return line
14 Cover for capsule
15 Air intake duct of capsule
16 Outgoing air duct
17 Exhaust silencer (encapsulated)
20 Cover for air duct housing
(Access to governor housing of engine)
22 Eye hook for transport, disappearing
max. load 500 kg
23 Engine brackets
25 Engine flange
26 Side panel
27 Cover, service side
28 Cover, outgoing air side
L / M . . 10.98 1
Operating side 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 for 9 Flywheel
cranking engine 10 Engine flange
10 Oil drain plug 11 Starter motor
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
1 L / M . . 10.98
Operating side Governor- and exhaust side
Engine: H 2 L 30, Engine: H 2 L 30,

H 3 L 30 H 3 L 30
1 Cooling water inlet
1 Fuel line (feed pump - filter) 2 Rain protection cap
2 Fuel line (filter - injector pumps) 3 Air filter
3 Hose connection 4 Cylinder head cover
(Maintenance indicator for air filter) 5 Fuel pressure pipe
4 Primer pump 6 Temperature switch
5 Fuel feed line 7 Cooling water outlet
(Fuel tank - fuel feed pump) 8 Exhaust manifold
6 Lub.-oil filling and dipstick 9 Starter motor
7 Speed control lever 10 Type plate
8 Solenoid, engine stop 11 Centrifugal pump
9 V-belt 12 Belt-adjustment link
10 Voltage regulator 13 Alternator
11 Oil drain plug, governor side
12 Lub.-oil filter IMPORTANT !
13 Oil drain plug, The standard transport suspension enables
14 Fuel pre-filter safe transportation of the engine including
15 Oil pressure switch supplementary equipments, and is designed
16 Fuel feed pump (Bosch) for a maximum load of 500 kg (1100 lbs).
It is neither suitable nor approved to lift
complete units.
L / M . . 10.98 1
Type plate data
Engine number
Type-No. 064 10 81 031814
Engine series no.:

The serial no. begins
Complete type description with 10 and changes
continously (11,12) if
2 L 40 C any major changes are
e.g. carried out.
Engine type
Year of production
Engine version Fabrication-No. (continous)
Customer spec. list No. 1)

Customer-specification
MOTORENFABRIK HATZGMBH
+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 cm3
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
1 L / M . . 10.98
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 – on engines with oil cooler
oil servo 12 Oil suction strainer
5 Crankshaft 13 Balancing shaft(s)
6 Main bearings 14 Lub. oil filter with bypass valve
7 Hydraulic belt tensioner 15 Oil cooler
8 Lubricating oil pump 16 Oil pressure switch
9 Sump 17 Oil pressure relief valve
L / M . . 10.98 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
n = 3000 rpm m3/min 25 - 35 - 45
Combustion air requirement
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 rpm min.: 0.9 bar
Lubricating oil consumption max.: 1 % of fuel consumption, at full load
Starter motor 12 V, 2,7 kW or 24 V, 4,0 kW
Alternator 14 V, 50 A or 28 V, 40 A*
Battery 12 V, 88 / 143 Ah or 24 V, 55 / 110 Ah
Max. continuous inclination with and without with without only with
towards oil sump oil sump oil sump
Operating side 30° 30° 25° 25°

Flywheel side 30° 22° 25° 18°
Air outlet/starter side 30° 30° 30° 30°
Governor side 30° 25° 25° 15°
* At H 2 L 30 and H 3 L 30: 14 V, 33 A or 28 V, 27 A
1 L / M . . 10.98
Technical data L 31, M 31, L 40, M 40
Type 2L31 2L40 3L31 3L40 4L31 4L40

2M31 2M40 3M31 3M40 4M31 4M40
Combustion system Direct injection
Bore / stroke mm 102/90 102/105 102/90 102/105 102/90 102/105
Displacemen cm3 1470 1716 2205 2574 2940 3432
Compression ratio 18:1
Firing order, cyl.1: timing end 2-1 1-3-2 1-3-4-2
Kühlluftbedarf bei
n = 3000 min-1 m3/min 25 29 35 39 46 49
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
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

L / M . . 10.98 1
Technical data L 41, M 41
Type 2L41 3L41 4L41

2M41 3M41 4M41
Combustion Direct injection
Bore / stroke mm 102/105 102/105 102/105
Displacement cm3 1716 2574 3432
Compression ratio 18,7:1
Firing order, cyl.1:timing end 2-1 1-3-2 1-3-4-2
Cooling air requirement at
n = 3000 rpm m3/min 29 39 49
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
Lubricating oil consumption max.: 0,2 % of fuel consumption, at full load
Starter motor 12 V, 2.7 kW or 24 V, 4.0 kW
Alternator 14 V, 50 A or 28 V, 40 A

1 L / M . . 10.98
Sealants and adhesives
Sealants and adhesives:
Code letters in the text and drawings 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
L / M . . 10.98 1
Special tools and workshop equipment
Series L / M engines
No. Ident-Nr. Code Item

1 669 350 00 03.1.1 Pressing-in drift ∅ 9 mm for valve guides
2 612 110 00 03.1.2 Reamer 9 H 6 for valve guide
3 668 383 00 01.1.2 Clamp for fuel line
4 626 753 91 03.1.1 Impact extractor with accessories
5 630 094 00 03.1.2 Test nozzle 400 bar
6 629 223 01 03.1.2 Valve lifting tool
7 625 739 00 03.2.1 Pressing-in drift for valve stem seal
8 612 092 00 03.1.2 6 mm intl. hex. insert with centering pin
9 665 418 00 05.2.1 Driver sleeve for camshaft bearings
10 665 030 91 05.1.1 Overflow device for injection pump
11 612 087 00 05.1.2 Dial gauge – 1/100 mm
12 634 142 00 03.1.2 Honing tool
13 620 926 01 03.1.1 Oil pressure gauge 0 -6 6 bar with flexible tube
14 624 838 91 03.1.2 Rev. meter for fuel pressure pipe
15 625 383 02 03.1.2 Digital multimeter
16 612 090 01 03.1.2 Piston ring pliers
17 626 383 00 03.1.2 Piston ring clamping tool ∅ 70 - 100 mm
18 624 845 01 03.2.2 Crimping pliers up to 6 mm2
19 633 178 00 06.2.1 Relay test box
20 631 191 00 06.1.2 Puller for belt tensioner bushings
21 631 203 00 06.1.2 Installation drift for belt tensioner bushings
22 632 913 00 05.1.1 High-pressure pump cpl.
1 L / M . . 10.98
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18
box
ns- und Test
Relais-Funktio
87a 50
15 87
86
Injection - pump
– +
timing set
D
E C
B
A
19 20 21 22
L / M . . 10.98 1
Series L / M engines
No. Ident-Nr. Code Item

23 624 340 01 05.1.1 Marking device for radial position of injection pump
24 624 346 01 05.1.1 Gauge for measuring governor rod travel
25 624 347 00 05.1.1 Gauge for adjusting start of fuel injection
26 624 348 01 05.1.1 Calibrating device for tool - 25 -
27 624 349 00 05.1.1 Locating pin for governor rod
28 624 350 00 05.1.1 Fuel injection volume adjusting tool
29 606 000 00 05.1.1 Wrench for starting charge adjustment
(mechanical system only)
30 618 140 01 03.1.1 Multipurpose puller in connection with tool - 31 -
31 618 418 00 03.1.1 Forcing-off screw for tool - 30 -
32 610 390 00 03.1.1 Forcing-off screw for centrifugal clutch
33 620 300 00 03.1.1 Forcing-off screw for centrifugal belt pulley
34 624 393 00 05.1.1 Assembly sleeve
35 621 056 00 03.1.1 M 10 x 1 guide pin for conrod
36 626 211 00 03.1.1 M 11 x 1 guide pin for conrod
37 604 628 00 03.1.1 Test pressure gauge for fuel injection system
38 620 307 01 01.1.2 Strap wrench
39 620 638 01 02.1.1 Locking device for tensioning roller
40 619 746 00 05.1.1 Holder for injection timer assembly
41 630 439 00 05.2.1 Gauge for oil spray nozzles
42 619 852 02 5Q.1.1 Air guide plate for 2 L / M
45 624 863 02 03.2.1 Elevating table, mobile
46 624 864 01 03.2.1 Adapter elements for - 45 -
47 629 055 00 02.1.2 Disassembly tools for cable plug
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 . . 10.98
23 24 25 26 27
28 29 30 31 32 / 33 34
35 / 36 37 38 39
46
40
42
43
44 44
47 45
L / M . . 10.98 1
2. Additional equipment
L / M . . 09.96 2
A 01.00 Fuel
A 01.40 Fuel delivery pump
-3-
General:
2
– When installing the fuel delivery pump,
make sure that the delivery and suction 3
lines are connected correctly. 4 12
Dismantling: 5 6
– Disconnect fuel feed line with clamp - 3 -.
– Separate the fuel lines from the delivery
pump.
– Unscrew and remove nuts with spring 1
washers, and take off fuel delivery 7
pump with O-ring. 8
– Dismantle fuel delivery pump 1 in the 9
numerical order of parts illustrated 10
(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. 182
This input-side filter is supplied as a spare
part with the fuel delivery pump and also
with the repair kit for the fuel delivery
pump.
Assembling:
Assemble by following the instructions in
the reverse order as appropriate.
2 L / M . . 09.96
A 03.00 Exhausts
A 03.12 Removing and installing the silencer (muffler)
enclosure(L 30, L 31, L 40, C/K)
–
3
Preparations:
– Remove the hood from the enclosure
and air outlet duct; see M 35.00.
4
Detaching:
– Take out hex bolts (184/1) and detach
the connecting stub pipe with exhaust
pipe (184/2).
On more recent versions, the exhaust
pipe is secured with a clip. 2 1
– Take out the machine screws (184/3) L3 / 228
and remove the connecting cover
184
(184/4).
– Unscrew and remove the hex bolts 1

(185/1).
L3 / 229
185
– Remove the machine screws (186/1) 1

and bolts (186/2).
L3 / 230
186
L / M . . 09.96
Downloaded from www.Manualslib.com manuals search engine 2
Lift off the enclosure 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 manufac-

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

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

– Examine the enclosure sections and the
silencer for fractured welds or tapped
holes which are unfit for further use.
Installing:
– Install by following the removal instruc-
tions in the reverse order as L3 / 232
appropriate.
188
The silencer must be installed without
trapped stresses (a two-piece holder for
the silencer has been installed since
March 1989).
Note:
Before installing the connecting stub pipe
(189/1), check free movement of the seal-
ing washer (189/2).
Place the sealing washer in the connect-
ing stub pipe and install the plate (189/3).
It should be possible to move the sealing
washer radially. Next, place the sealing 1 2 3
washer on the silencer. Radial play must
not exceed 0.1 mm. If necessary, renew
the sealing washer. L3 / 233
189
2 L / M . . 09.96
A 04.00 Start mechanical

–
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.
Attention !
There is a risk of injury if the shaft of the
crank handle or its tubular handgrip are
worn.
Preparations: –
Demontage: –
Inspection / repair:
– Visual inspection. 2
– Inspect shaft 1 and tubular handgrip 2
for wear or breakage. 1
Note:
If the shaft of the crank handle is worn,
always renew the complete handle.
The tubular handgrip can be renewed 191
separately if necessary.
L / M . . 09.96 2

–
Version A 04.10.2
Handle with kick-back damping:
The version for M .. engines is marked A
on its housing, and takes the place of the
standard crank handle if required.
Attention !
4 7
There is a risk of injury if the shaft of the
crank handle or its tubular handgrip are
worn. 12 8
11
Preparations: –
3
Demontage: 15 10
– Remove parts in the order 1 ... 3 as 14 13
illustrated. A 16
15
– Remove machine screws 4. 9
– Take off cover 5 with great care, so that 6
5
leaf spring 11 cannot escape.
Risk of injury!
– Remove parts in the order 6 ... 10 as
illustrated. 192
– Hold torsion spring 13 in position in
order to maintain its tension.
– Pull leaf spring 11 away from its locking
pin and out of the hook eye on torsion
spring 13.
– Relieve torsion spring tension with a
screwdriver blade.
Caution - risk of injury!
– Take off parts 12 and 13.
Housing 14 remains in position with the
other parts.
2 L / M . . 09.96
Inspection / repair: 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 – Make sure that the torsion spring is not
cover 5 and/or housing 14. trapped; insert its longer end into the
– If necessary, renew pivot bushings 15 groove on the corresponding locating
and shaft sealing ring 16. pin.
– Examine tubular handgrip 7 for wear – Preload torsion spring 13 against the
and/or other damage, particularly in the normal spring pressure until the hook
splined area. eye of the spring engages behind the
– Install end plug 8, avoiding damage to eye of the through-hole.
the splines. The end plug must installed Caution - risk of injury!
to prevent dirt and water from entering. – Hold torsion spring 13 in position to pre-
– Check condition of bushing and leaf vent spring pressure from being lost.
spring at lever 9. – Push leaf spring 11 into the hook eye
– Check condition of leaf spring 11 and on torsion spring 13 and place on
torsion spring 13. locking pin.The rolled end of the leaf
Renew in case of doubt. spring must face toward the center of
– Check shaft 3 for wear and/or other the housing.
forms of damage. – Attach lever 9.
– Renew O-rings and small parts. – Push on tubular handgrip 7/8.
Check splines, lever and leaf springs for
free movement.
– Apply app. 50 grams of lubricant K to
the inside of housing 14 and over all
mechanical parts.
– Place a new gasket 6 on the housing.
– Carefully place cover 6 over tubular
handle 7.
– Insert machine screws 4 and tighten
them evenly in a crosswise pattern.
– Install shaft 3 in the order 3 ...1 as
illustrated.
– Check operation of the complete crank
handle.
L / M . . 09.96 2
A 04.20 Automatic decompressor (M 31, M 40, M 41)

–
The automatic decompressor has the

following positions; Fig. 93:
0 = Operating position, with engine
running
1 = Permanent decompression, automatic
device switched off
2 = Automatic decompressor switched on, 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 second 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). L3 / 42
– Using a suitable split-pin driver, drive
locking collet (94/16) about 3 mm into 94
gearwheel (94/21).
– Turn the gearwheel through 180° and
pull the locking collet out with pliers.
– Take out shaft (94/14) and gearwheel.
2 L / M . . 09.96
Checking parts:
– Inspect the gearwheel and cap for dam-
age caused by moving the decompres-
sion 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 instruc-
tions in the reverse order as appropriate.
Note:
– With the automatic decompressor in
position „0“, note the correct position of
the gearwheel (Fig. 95).
max. 46.1 mm
min. 45.5 mm
– Check that the lifting pin can move b c
freely.
– When installing threaded rod (94/19),
make sure that pressure pin (94/17)
engaged in the locating slot on shaft
(94/14).
B
Adjusting the automatic
A
decompressor:
L3 / 43
Adjustment is needed if:
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
dimension „B“; Fig. 95.
Note:
For this check, the rocker should rest
lightly on the valve stem but without open-
ing the valve (turn the engine over until
the tappet is resting on the base circle of
the cam).
L / M . . 09.96 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
drive it out.
– Install the rocker temporarily, insert the
new pressure pin (95/b) and place
shims (95/c) under it to the required
thickness, until the correct dimension
(95/B) is reached.
Note that when it is riveted into position,
the pressure pin is about 0.1 mm lower.
– Rivet the pressure pin into position,
pressing it firmly into the bore. The
pressure pin should project by at least
1 mm at the riveting point, to ensure
firm seating. If it does not project
sufficiently, grind the rocker away slight-
ly at the appropriate point.
Install the rocker finally, noting the
endplay; adjust valve clearance and
check dimension (95/B) again.
Checking dimension „A“:

– Using a depth gauge, determine dimen-
sion „A“ (Fig. 95); work out the number
of shim washers (94/9) needed
according to the table, and secure them
with the pressure pin (94/10) to the Dimension Number of shim
actuating pin (94/8). „A“ in mm washers (Fig.94/9)
– Check operation of the automatic 14,0 - 14,5 6
decompressor. 14,5 - 15,0 5
When decompression is active, it must 15,0 - 15,5 4
be possible to turn the engine over with- 15,5 - 16,0 3
out compression resistance, but the 16,0 - 16,5 2
exhaust valve must never strike the 16,5 - 17,0 1
piston. 17,0 - 17,5 0
2 L / M . . 09.96
A 04.70 Recoil starter

–
Preparations:
– Remove the silencer (muffler);
see A 03.00.
– Remove the fan; see M 13.0
Detaching the recoil starter: (Fig. 190)

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

here.
L / M . . 09.96 2
A 04.80 Start release device (L /M 31/40/41)
–
Preparations: 1
– On C/K, take off hood at enclosure and
side panel; see M 35.00.
– On S/Z and M.., take off side panel and
cooling air duct for lubricating oil cooler.
Detaching and dismantling:

2
– Pull off fuel lines (113/1 and 2). Take out
start release device retaining screws
and remove the device. 1
– Take off spring (114/9), flexible gaiter
(8) and nut (6); take off cylinder (114/2) 113
and remove lock washer (114/5), lever
(4) and washer (7)..
5 2
Checking parts:
– Place the cylinder (114/2) in a tank con-
taining diesel oil. Apply an air pressure
4
of max. 1.5 bar to the hose line (114/1). 6 7
If air bubbles emerge from the cylinder, 14
it must be renewed. 8
– Check flexible gaiter for damage and
3
renew if necessary. 13
Re-assembling the start release device:
Follow the dismantling instructions in 9
reverse order as appropriate; refer to Fig.
114. 114
Note:
When attaching to the engine monitoring
block, make sure that locking collet
(114/13) is pressed into the start position
by lever (114/4), or else the start release
action will not take place; see also Fig.
116/1.
Stop
Before tightening machine screws
(114/14), move bracket (114/3) in the
opposite direction (see Fig. 116/2), to
ensure that locking collet (114/13) can
move as far as possible back to the „Stop“
position.
115
2 L / M . . 09.96
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, i.e. the engine is not
shut down automatically if lubricating oil
level drops too low.
– On older engine versions, hose (113/1)
is connected to the fuel delivery pump.
This has no effect on the basic function
of the device.
Operational check with start release

device installed:
– Turn lever (114/4) clockwise; locking
collet (114/13) must move to the „Stop“
position (Fig. 116). Release the lever;
the locking collet must move back to the 1
„Start“ position.
– Prime the fuel delivery pump with the

lever and at the same time check rt
whether the piston in cylinders (114/2) Sta
moves the lever (114/4) correctly. Also
check the cylinder and hose unions for
leaks. When the lever is no longer
actuated, spring (114/9) exters pressure
on the piston, which should then move 2
back slowly (see Fig. 116).
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 protec-
tion device will be put out of action and
the engine then cannot be switched-off
electrically.
L / M . . 09.96 2
A 05.00 Start electrical
General instructions on the engine's Checking operation of the alternator

electrical system: with voltage regulator (checking
– Never interchange the positive and neg- charging current):
ative terminals at the battery. – With the engine stopped and the
– Do not disconnect the battery when the starting-switch key at „0“, detach the
engine is running. B + line (leading to the battery) from the
– Avoid all risk of short-circuiting live alternator and connect a DC ammeter
cables (for instance, never test whether with a scale reading of 0 .. 50 A
a cable is live by touching it to earth). between alternator terminal B + and the
– If the charge telltale light bulb blows, detached cable. Make sure that the
replace it immediately. loose cable cannot touch any metal
– If any welding is done on the engine or parts of the engine.
the equipment to which it is fitted, – Connect a DC voltmeter with a scale of
attach the earth (ground) clip of the 0 . . 30 V to the battery's positive and
welding set as close to the weld area as negative poles.
possible, and disconnect the alternator – Start the engine and note the meter
from the electrical circuit at connections readings. Check the voltmeter display.
„B +“ and „D -“. With the alternator in good working
– When cleaning the engine, avoid order and electrical consumers in
spraying water on the alternator or any circuit, the ammeter should indicate a
other components of the electrical charging current. Its value depends on
system. the battery's state of charge (if the
If this is unavoidable, first disconnect battery is flat, the charging current is
the battery; before it is reconnected, dry high, if the battery is fully charged, the
all components thoroughly with a charging current is low), but also on the
compressed air jet. consumpition of electrical equipment
– If a malfunction, for instance low battery actually in use and on alternator and
charge, charge telltale light on etc, therefore engine running speed. If there
should be detected, always check the are no consumers in circuit, a charging
tightness of cable connections and current should even be indicated at idle
correct V-belt tension before making any speed. If the alternator voltage is too
other operational checks. high, renew the voltage regulator.
– For trouble-shooting in the event of a
fault, see section 4. System
Test values
– When recharging the battery, 12 V 24 V
disconnect the negative terminal. 13.0 -
Voltmeter reading 14.5 V 26 - 29 V
– Avoid using electrical starting aids
because of the risk of voltage peaks Charging current at
(these could damage electronic 13.5 V or 27 V
components). Battery voltage-
– Engine speed approx. approx.
800 rpm (idle) 25 A 5A
– Engine speed
1500 rpm 40-45 A 25-30 A
2 L / M . . 09.96
A 05.00 Start electrical
A 05.40 Alternator (air-cooled engines)

–
Preparations:
Encapsulated engines:
– Take off the hood, the air guide housing
cover and the impeller wheel. Unscrew
and remove the enclosure side panel;
see M 35.00.
– Take off the Poly-V belt; see M 20.00.
Non-encapsulated engines:
– Unscrew and remove the V-belt guard if
attached.
– Take off the air guide plate.
– Take off the Poly-V belt; see M 20.00.
Removing:
– Detach the earth (ground) lead from the 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
striking it with a plastic-faced hammer;
see Fig. 123.
Checking parts:
– Examine the fan and the belt pulley for
evidence of damage.
– If any grooves have broken away or are
damaged, renew the fan with belt pulley.
Installing:
– Install the rotor and the alternator by
following the above removal instructions
in the reverse order as appropriate.
Note:
When connecting the cables to the alterna-
tor, make sure they are not accidentally
interchanged. 194
L / M . . 09.96 2
Notes on renewing the alternator:
When series production of Series L / M

engines began, alternators made by SEV-
MARCHAL were used.
These alternators are no longer available
as spare parts, but can be replaced
without difficulty by the current VALEO
alternator.
The MARCHAL voltage regulator is still
available.
In view of the modified installed position
of the voltage regulator on PARIS-
RHONE or VALEO alternators (removal
and installation in a radial direction to
reduce the risk of breaking off the carbon
brushes), the fan housing was also 195
modified in the regulator area when the
PARIS-RHONE generator was introduced.
A cutout in the housing and deletion of
the retaining screw which previously
passed through at this point ensure that
the regulator switch can be renewed with-
out having to remove the alternator.
When replacing a MARCHAL alternator

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

regulator, make sure that the condenser
supplied with it is also installed (connec-
tion diagram is enclosed).
2 L / M . . 09.96
A 07.10 Oil cooler (air-cooled engines)
–
Preparations:
– On engines with enclosure, take off
the enclosure hood and side panel;
see M 35.00.
– On engines without enclosure, take off 1
the cooling air duct to the oil cooler.
Removing block-pattern oil cooler:

– Remove the oil line to the servo (only
on older version of the engine).
– Take out machine screws (196/1) and
L3 / 189
detach the oil cooler.
196
Removing gilled-tube oil cooler:
– Take out machine screws (197/1) with
spring washers and detach oil cooler
with sealing rings (197/5). 1 2 5
– To dismantle the oil cooler: Pull the oil
guides (197/2) apart and take out both
gilled tubes (197/3) with O-ring seals
(197/4).
Note:
The gilled-tube oil cooler is only used on
two-cylinder engines without enclosure
and rated for engine speeds up to a 3 4 2
certain limit. 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
appropriate removal instructions in the
reverse order.
Retrofitting engine with oil cooler:

– If an engine has an oil cooler retrofitted,
the missing threaded rod (198/3) must
be inserted and secured with sealant D. L3 / 190
Unless this work is performed, the oil
cooler will be unable to operate. 198
L / M . . 09.96 2
A 07.11 Oil cooler (water-cooled engines)
–
Preparations:
– Drain the coolant.
– Detach the coolant lines from the oil
cooler.
Removing::
– Take off the oil filter (199/1). 5
– Unscrew and remove the threaded
sleeve (199/2).
– Take off the oil cooler (199/3) with spac- 4
ing ring (199/4) and O-ring seal (199/5). 3
1 2
Checking parts:
– Make a visual check for cracks or
damage to the sealing faces. 199
Installing:
– Install the oil cooler by following the
removal instructions in the reverse order
as appropriate.
Note:
– Install the oil cooler side with the
sealing ring towards spacing ring
(199/4).
– Tighten threaded sleeve (199/2) to a
torque of 55 Nm.
2 L / M . . 09.96
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)
–
Demontage:
– Disconnect the solenoid and take off the
starting aid housing, taking care not to
turn the volume limiting eccentric.
remove solenoid (205/2). 1
– Pull eccentric shaft (205/3) towards the 10 2
solenoid 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).
– Use a new O-ring seal (205/10).
– Check flexible gaiter for damage and 6
8
renew if necessary.
7 5
Assembling:
– Proceed in the opposite reverse; install 4 9
end cap (205/9) with sealant C. L3 / 199
205
L / M . . 09.96 2
Adjusting engine shutdown and
solenoid:
The solenoid does not need adjusting
unless the adjusting nuts were turned or a
new solenoid has been installed.
– Press in the solenoid fully against the 2
spring loading.
– Insert solenoid adjusting gauge
1
621 471 00 (206/1) into the hole in the
housing; see Fig. 206.
– Turn adjusting nut (207/1) until lever
(206/2) is touching the adjusting tool.
Note: 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“ posi-
tion.
– Coat both sides of the gasket (208/1)
ì 0.1
for the housing with sealant H. Apply
only a thin coat of the sealant so that
39.3
the oil passage in the starting fuel L3 / 201
supply device is not blocked. 207
– Attach the gasket (note correct position
of oil hole) and press the solenoid by
hand into the operating position: angle
(208/3) must engage to the left of the
driver pin on governor rod (208/4). 4 2
– In this position, attach the housing and
reconnect the solenoid.
Attention!
If the angle is positioned incorrectly when 3
installed (at the right of the driver pin), the 1
engine will overspeed and could destroy
itself unless the solenoid is put out of
action immediately.
When the U-pattern driver pin was
introduced, incorrect positioning as L3 / 202
described above was ruled out. 208
2 L / M . . 09.96
A 11.00 Automatic devices
A 11.70 Temperature-controlled starting fuel volume control
- 24 - 28 -
Adjusting: 4
– Screw in adjusting tool - 28 - and attach
measuring device - 24 -. 3 2 1
– Pull the speed control lever briefly to
„Stop“ and then to the full-load
position.This places governor lever 1
against full-load stop 2 of the starting
fuel volume control.
– Zero the dial gauge.
– Screw thermo-element 4 carefully into
the bracket, until the dial gauge just
begins to move (the sickle-shaped lever
is then against the governor rod).
– Unscrew adjusting tool - 28 - at the
13 mm hexagon until a clicking sound is 170
clearly heard, to indicate that the gover-
nor lever is dropping into the increased-
volume starting position.
– Slowly turn thermo-element 4 back to a
lower setting until the dial gauge indi-
cates a movement of 0.2 mm towards
increased volume from the zero position
previously obtained.
– In this position, secure the thermo-
element with the locknut.
– Detach auxiliary tools and install any
engine components not yet in place.
Attention:
When adjusting, make sure that the
thermo-element is at a temperature of at
least 20°C.
L / M . . 09.96 2
A 15.00 Housing
A 15.20 Connecting housing
–
Assembling:
– Drive locking collets (200/1) into the
crankcase.
– Attach the connecting housing, insert
2 3
four M 14 x 1.5 mm hex bolts (200/2)
1
with spring washer (200/3) and tighten 4
to the specified torque.
Note:
Apply sealant D to the bolt above
inspection hole (200/4), since this is a
through-hole. 5 6
On engines without a connecting
housing, the equivalent screw plug should L3 / 143
also be coated with sealant D before
inserting. 200
– Insert and tighten the two lower M 10
hex bolts (200/5) with spring washers
(200/6).
2 L / M . . 09.96
A 30.20 Water pump (H.L 30)
–
Preparations:
– Drain the coolant.
– Take off the alternator.
Dismantling:
(Fig. 201)
– Detach the coolant lines at the water
pump.
– Unscrew hex bolts 1 with spring 2 1
washers 2 and take off the water pump.
– Remove screws 3 with spring washers 4
and take off V-belt pulley 5. 7 6
– Take out screws 6 with copper washers
7 and remove pump element 8 with seal
9 from housing 10. 10 4
9
Checking parts: 8
– Check housing for evidence of damage. 5 3
Note:
If the following damage is detected, renew 201
complete pump element 8:
– Damaged pump impeller.
– Worn sealing ring in pump element
(water leaking from the hole in the
pump element).
– Bearing worn.
Assembling:
– Assemble by following the dismantling
instructions in the reverse order as
appropriate.Install pump element 8 with
the water drain hole facing down.
L / M . . 09.96 2
A 30.40 Thermostat (H.L 30)
–
Preparations:
– Drain the coolant (only needed if the
1
upper edge of the radiator is higher than
the thermostat). 2
– Detach the coolant line from thermostat 3
cover (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 202

insert:
Note:
The temperatures stamped on the
thermostat insert indicate the start of its
opening movement and the maximum
operating temperature.
– Suspend the thermostat insert and a
thermometer in the centre of a vessel
filled with water; see Fig. 203.
– Heat the water while stirring it.
– Check that the thermostat insert opens
at the temperature stamped on it.
– Remove the thermostat insert and check
that it closes correctly.
– Renew thermostat insert if defective.
203
Assembling:
– Clean the sealing faces on the cylinder
head, the thermostat cover and the seat
of the thermostat insert.
– Install the thermostat insert, using a new
sealing ring (the arrow stamped on it
indicates the direction of flow).
– Attach the thermostat cover again and
tighten its screws uniformly.
2 L / M . . 09.96
3. Basic engine
L / M . . 09.96 3
M 01.00 Crankcase
M 01.10 Removing and installing balancing weights - 2L / 3L

–
Preparations:
– Remove the crankshaft, see M 02.00.
Dismantling:
– Unscrew and remove machine screws
(1/1) at driver (1/2).
Note:
On the 3 L, also unscrew and remove the
machine screws at the divided driver.
– Unscrew and remove the machine

screws (2/1) at the plate (2/2) and take 1
off the plate.(On more recent version:
secured with stud bolts and nuts)
– Unscrew the plug from the thrust bus-
hing at the timing end of the engine 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.
– Check the shaft at its bearing points for
score-marks and correct dimensions; for 2
values, see Section 4.
– Check the needle roller bearings of the
balancing weights for score-marks.
– Check the gearwheel with balancing
weight and the crankshaft-end gear-
wheel for the balancing weights for
signs of damage.
– Renew the O-ring seals at the thrust
bushings.
3 L / M . . 09.96
Assembling:
– Insert the thrush bushing (timing end)
until flush with the housing.
– Place the gearwheel with balancing
weight (flywheel end) and the balancing
weight (timing end) in the lower part of
the crankcase, insert the driver and
screw hand-tight to the balancing
weights. Insert the shaft with thrust bus-
hing (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 dri-

ver and use a depth gauge to measure
endplay at the balancing weights; see
Fig. 5.
Note:
The timing-end thrust bushing (5/1) forms
part of the sealing face at the timing case
cover, and must therefore be flush with
the endface of the crankcase after driving
in the shaft.
Endplay can be adjusted by moving the
flywheel-end thrust bushing axially until 5
the value stated in Section 4 is obtained.
– 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
crankcase cover, apply sealant D to two
M8 hex bolts in each case at the timing
and flywheel ends, where a through-hole
has been drilled. 6
L / M . . 09.96 3
M 01.00 Crankcase
M 01.20 Removing and installing balancing weights - 4 L
–
Preparations:
– Remove the crankshaft; see M 02.00.
– Take off the oil sump.
Dismantling:
– Unscrew the machine screws (7/1) at
the bearing journals (7/2) and pull them
out.Using two machine screws, loosen
the bearing journals and pull them
out.Mark the installed positions of the
bearing journals.
– Invert the lower part of the crankcase.
Note:
The joint line is a sealing face, and must
not be damaged. Place the crankcase on
a wooden grid or frame; see Fig. 8.
– Unscrew splash plate (9/1) and take out

balancing weights (9/2), then remove
splash plate (9/3).
3 L / M . . 09.96
– 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).
– Check the bearing journals and bus-
hings 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 cor-
rect position; see Fig. 11.
11
– Coat the bearing bushings (12/1) with

sealant D and drive them into the hou-
sing until flush, using a suitable drift;
see Fig. 12.
– Coat the sealing faces of the end caps
(10/2) with sealant C and insert them
again.
– Renew the end caps.
12
L / M . . 09.96 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,

insert the lower machine screws (14/1)
and tighten them. Screw the upper ma-
chine 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
3 L / M . . 09.96
– Insert the balancing weight with circle
mark (16/1) and push in the bearing
journal.
Note:
When installing this balancing weight
(16/1), make sure that the circle mark on
it is between the two line marks on balan-
ce weight (16/2).
In this position, the circle mark on balan-
cing weight (16/2) must face the cranks-
haft.
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 tigh-
ten; also tighten hex bolts (17/4).
– Turn the lower part of the crankcase

back upright again (joint line at the top).
– Insert the machine screws at the bea- 17
ring 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 sea-
lant D to two M8 hex bolts in each case at
the timing and flywheel ends, since these
are inserted in through-holes.
Engines with an oil sump attached must
not have a ∅ 40 mm end cap in the lower
part of crankcase.
18
L / M . . 09.96 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 oil-
ways and, after cleaning the crankcase
by immersion 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 remain.
– After this, insert all screw plugs again
and check that the aluminium or sheet-
metal plugs for the oilways are firmly
seated. In case of doubt, renew them;
apply sealant E to all plugs before inser-
ting. To ensure firm location, secure the
aluminium plugs with light punch-marks 171
at the edge of the hole in the housing.
Oil spray jets
– First check for firm location and accura-
te spray direction; if necessary, re-align
the spray jet with light hammer-blows or
bend it carefully by hand until the cor-
rect position is reached. Check this with
the gauge - 41 -or work from the dra-
wing shown here (Fig. 171).
If oil spray jets have broken off or are loo-
se, new ones must be inserted. Proceed
as follows:
– Remove pieces of the old jet from the
drillway (with a suitable drift or similar
tool); degrease the entire area tho-
roughly; insert the new spray jet and
drive it in initially app. 6 - 8 mm farther
than its final position. Strike the projec-
ting end lightly with a hammer to bend it
slightly and ensure a firm seating in the
bore (Fig. 172).
172
3 L / M . . 09.96
– Apply sealant E to the projecting end
and move the spray jet to its final posi-
tion. Do not dent the jet inlet bore; drive
it in until the end of the tube is flush
with the oil groove in the bearing seat
(Fig. 173).
– Check the position of the jet outlet
again, and adjust if necessary.
– Apply sealant E again where the spray
jet passes through opposite the bearing
seat; the capillary action of the sealant
will ensure that the tube is fully coated
and cannot shake loose in its seat.
Note:
On Series L 41 and M 41 engines, an oil
spray jet is also installed for cylinder 1.
173
L / M . . 09.96 3
M 02.00 Crankshaft
-8-
Preparations:
– Take off enclosure parts and air guide
plates; see M 35.00.
– Take off cylinder heads; see M 07.00.
– Detach fan and V-belt pulley from
crankshaft; see M 13.00.
– Remove piston, conrod and cylinder;
see M 05.00 / M 06.00.
– Take off flywheel and connecting hou-
sing.
– Detach the timing case cover;
19
see M 11.00.
– Take off the starter motor.
Dismantling:
– Remove machine screws and spring
washers for end cover and pull off the
end cover; see Fig. 19.
– Unscrew the machine screws(20/1) and

pull them out.
20
– Remove machine screws from cranks-

haft gearwheel, loosen the gearwheel
on the crankshaft with a plastic-faced
hammer and pull it off.
– Pull out the locking collet (21/1).
21
3 L / M . . 09.96
– Unscrew and remove the hex bolts
(22/1) at both sides.
22
– The two halves of the crankcase are se-

cured 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 up the upper part of
the crankcase vertically: Fig. 23.
Note:
To simplify the loosening and lifting off of
the upper part of the crankcase, insert
two M 8 x 65 machine screws (retaining
screws of setting-down device) at the
timing end and two M 14 x 50 hex bolts
(used to secure connecting housing) at
the flywheel end in the holes provided.
23
– Lift the crankshaft out of the lower part

of the crankcase.
– Carefully warm the balancing weight
gearwheel on the 2 and 3 L ... with a
welding torch and knock it off with an
aluminium drift.
For the 4 L ... crankshaft, unscrew and
remove the flywheel-end counterweight,
remove the machine screws for the
gearwheel and drive out the straight pin
(24/1).
24
L / M . . 09.96 3
– Check all crankshaft bearing journals
for score-marks and incorrect dimen-
sions; 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 do-
ing so, use sealant E. Assembly instruc-
tions are included with the spare part.
– Renew the shaft sealing ring in the end
cover. 25
– Check the bearing shells for damage
and visible signs of wear.
Installing:
– Pull the balancing-weight gearwheel on
to the crankshaft.On the 2 and 3 L ..
crankshafts, unscrew and remove the
flywheel-end counterweight; this will ex-
pose the line marking (25/1) on the
crankshaft.
Heat the gearwheel to app. 125° C and
pull it on so that the line marking (25/1)
on the crankshaft is aligned with the „O“
marking (25/2) on the gearwheel; see
Fig. 25.
On the 4 L ... crankshaft, unscrew and re- 26
move the flywheel-end counterweight and
manoeuvre the balancing-weight gearw-
heel into position as shown in Fig. 26.
– Apply sealant C to the straight pin alt neu
(24/1) and drive it in.
– Apply sealant D to the machine screws
and tighten them to the specified tor-
que.
Note:
From mid-1994 on, a modified gearwheel
and different retaining screws were intro-
duced. The new screws are not to be
used with the old gearwheel (Fig. 27).
5,5 6,5
On the 2 and 3 L .. engines, do not install
the counterweights again until the crank-
shaft has been placed back in the lower 27
part of the crankcase.
3 L / M . . 09.96
– Place the thrust washers (28/1) on the
crankshaft so that the lubricating groo-
ves face the thrust face on the cranks-
haft. Insert the bearing half-shells (28/2)
into the lower part of the crankcase,
and apply oil to them.
28
– Place the crankshaft in the lower part of

the crankshaft and make sure that the
gearwheels mesh together as indicated
by the marks.
For 2 / 3 L ... see Fig. 29.
29
– For 4 L ... see Fig. 30.
30
L / M . . 09.96 3
– 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 al-
so on the intermediate webs of the
crankcase; see Fig. 31.
– Insert the bearing shells into the upper
part of the crankcase and coat them
with oil.
31
– Position the thrust washers so that the

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

them to the specified torque in the order
shown in Fig. 33.
33
3 L / M . . 09.96
– Check crankshaft endplay with a depth
gauge, Fig. 34, and compare it with the
desired value stated in Section 4.
34
– Drive the locking collet to secure the

gearwheel (21/1) into the end of the
crankshaft.
– Turn the camshafts until the two marks
(35/1) are aligned and the mark for the
crankshaft gearwheel faces downwards.
– Engage the crankshaft gearwheel, no-
ting the position of the mark, and tigh-
ten 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 speci-
fied torque.
36
L / M . . 09.96 3
M 04.00 Camshaft
M 04.10 Camshaft, valve gear
- 9 - 30 - 31 -
Preparations:
– Take off the upper part of the crankca-
se; see M 02.00.
Dismantling:
– Remove the circlip (37/1) at the cover,
pull the cover (37/2) out with water-
pump pliers and remove the shim
washers.
37
– Stand up the upper part of the crankca-

se, take the circlip (38/1) out of the sa-
fety groove and press the valve tappet
(38/2) off the camshaft.
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
3 L / M . . 09.96
– Remove the circlip and shim washers
and pull off the ball bearing with a two-
arm puller; see Fig. 40.
40
– If the gearwheel or camshaft is rene-

wed, use puller - 30 - with forcing-off
screw - 31 - to pull the gearwheel off
the camshaft; see Fig. 41.
– Inspect the camshaft bearing points and
the bearing bores in the crankcase for
score-marks and incorrect dimensions;
for values, see Section 4.
– Check the camshaft gearwheel for
score-marks.
– Check the camshaft ball bearings for
wear.
– Check the tappets for score-marks. 41
–Check the bores in the crankcase for the
tappets for score-marks and incorrect
dimensions; for values, see Section 4.
Assembling:
– Heat the camshaft gearwheel to approx.
150 - 200°C on a hotplate, and press 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 . . 09.96 3
– When installing a new camshaft, make
sure that there is no endplay between
the ball bearing and the circlip (43/1). If
necessary, insert shim washers (43/2).
43
– Install the camshaft, noting the correct

positions of the marks, and insert circlip
(44/1).
– Drive the camshaft towards the timing
end of the engine until the ball bearing
is in contact with the circlip (44/1).
– Insert shim washers (43/3), push in co-
ver 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). 44
– A special camshaft has been introduced
to operate the valves on the following
engines.It can be identified by an „H“
cast into the camshaft.
2 M 31 H from No. 841087 000008
3 M 31 H from No. 851087 000004
4 M 31 H from No. 861087 000004
2 M 40 H from No. 781487 001631
3 M 40 H from No. 791487 000952
4 M 40 H from No. 801487 000873
3 L / M . . 09.96
M 04.00 Camshaft
M 04.20 Camshaft for injection pump
- 9 - 30 - 31 -
Preparations:
– Remove the injection pump;
see M 14.00.
– Remove the engine speed control;
see M 32.00.
– Remove the starting-mixture charging
device; see M 12.00.
– Remove the fuel delivery pump.
Dismantling:
– See M 04.10.
Detaching the intermediate gearwheel:
Note:
The intermediate gearwheel can only be
pulled off after removing the injection
pump camshaft.
– Take off the circlip (45/1) and unscrew
the splash plate (45/2)
45
– Pull off the gearwheel with the puller

- 30 - and the forcing-off screw - 31 - :
see Fig. 46.
Note:
The two ball bearings in the intermediate
gearwheel are separated by a circlip.
– Check the camshaft bearing points and
the bearing points in the crankcase for
score-marks and incorrect dimensions;
– Check the ball bearings for the cams-
haft and the intermediate gearwheel for
wear.
46
L / M . . 09.96 3
Attaching the intermediate gearwheel:
Note:
The intermediate gear wheel must be in-
stalled before the camshaft for the injec-
tion pump is installed.
– Press the ball bearing into the interme-

diate gearwheel and pull the gearwheel
on using impact sleeve - 9 - , noting the
positions of the markings; see Fig. 47.
– Place the circlip on the shaft.
Note: 47
Before pulling on, place the intermediate
gearwheel uniformly on the shaft, to pre-
vent the shaft from being pushed into the
crankcase.
Installing the camshaft:

– See „Installing camshaft for valve gear“
(M 04.10).
Note:
The camshaft for L 40/M 40 is marked
„L 40“ next to the delivery pump drive
cam.
3 L / M . . 09.96
M 04.00 Camshaft
M 04.30 Governor and injection timer
- 30 - 31 - 40 -
Preparations:
– Removing camshaft for injection pump;
see M 04.20.
Dismantling the governor: (up to engine

serial number: 2 L 40.16, 3-4 L 40.15,.M
40.12 and .L 30 and H.L 30)
– Remove circlip (48/1) and pull out
governor spring (48/2).
– Detach spring from governor (48/3) and
push out pin (48/4) with roller sleeves
(48/5).
– Pull out spring sleeve (48/6) with pull
rod (48/7).
– Unscrew spring bridge (48/8) and take
off holder for governor weights (48/9).
Dismantling governor: (from engine 48

serial number: 2 L 40.17, 3-4 L 40.16, .M
40.13, and all L 31 and M 31 engines)
– Remove circlip (48a/51) and pull out
spacing ring (48a/50), spring plate
(48a/49) and governor spring (48a/45).
– Remove the spring at the governor col-
lar (48a/11) and push out pin (48a/38)
with roller sleeves (48a/37).
– Pull out the pull rod (48a/36), unscrew
the nuts (48a/44) and take off the spring
plate at the governor (48a/43), the loca-
ting washer (48a/42) and needle roller
race (48a/41), the shim washer (48a/40)
and the thrust washer (48a/39).
– Unscrew the spring bridge (48a/32) and
take off the holder for the governor
weights (48a/26). 48a
– Check al parts for damage and signs of
wear.
L / M . . 09.96 3
Pull off and dismantle the injection
timer:
– Using puller - 30 - with pressing-off
screw - 31 -, pull the injection timer off
the camshaft; see Fig. 49.
49
– Clamp the holder for injection timer as-

sembly - 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),
retaining blocks (51/2) and pins (51/3)
with coil springs (51/4).
– Unscrew and remove the cam tracks
(51/5).
– Examine the support disc and gear-
wheel in the centrifugal weight area for
score-marks.
– Inspect the coil springs and their retai-
ning blocks for damage.
– Check the centrifugal weights for score-
marks.
51
3 L / M . . 09.96
Assembling the injection timer:
– Assemble the injection timer by follo-
wing the dismantling instructions in the
reverse order.
Note:
The gearwheel and support disc were
modified at the beginning of 1992.
Parts from the old and new versions can-
not be combined.
If necessary, renew the complete injection
timer.
After placing the gearwheel on the sup- 52
port disc, check that the slots in the
gearwheel and support disc are aligned
– Turn the injection timer clockwise and

allow it to move back to check its free-
dom 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 . . 09.96 3
Assembling of governor:
– Assemble the governor by working the
reverse order of dismantling; refer to
Figs. 48 and 48a.
Note:
When assembling the governor make
quite sure that all moving parts are able
to move freely.
On L/M 31/40 engines there must be a
clearance of 0.5 mm between spring plate
(48a/43) and nut (48a/44).
On L/M 41 engines the spring plate
(48a/43) must be held firmly when nut
(48a/44) is tightened. 55
– Install the spring for the governor (55/1)

so that the endface of the tapered sec-
tion points in the direction of rotation.
Renewing governor spring:

(without detaching the timing case cover)
Preparations:
– Remove the engine shutdown device;
see M 20.00.
– On the H.L30 take off the cover;
see M 11.00.
Dismantling:
– Remove circlip (56/1) and spring plate
(56/2).
– Take out governor spring (56/3) and
check it for cracks or breakage.
Assembling:
– Choose the correct new governor spring
as stated in Section 4, according to the
engine's intended use and speed range. 56
– Install the governor spring or engine
shutdown device by working in the
reverse order for removal.
3 L / M . . 09.96
M 05.00 Conrod
- 35 - 36 -
Preparations:
– Take off the cylinder head; see M 07.00.
– Remove the cylinder and piston;
see M 06.00.
Dismantling:
– Unscrew and remove the big-end bolts
(62/1) and lift out the conrod and big
end cap with the aid of guide pin
- 35 - or - 36 -.
– Check the conrod bushing, big end bea- 62
ring and crankpin for score-marks and
incorrect dimensions; for values, see
Section 4.
Assembling:
– Press the bushing into the conrod.
Note:
When pressing in the conrod bushing,
make sure that the oil holes are aligned
and that the bushing projects by an equal
amount on each side.
– Insert the big end bearing half-shells
into the conrod, making sure that the
locating nuts are in the grooves provi-
ded; see Fig. 63. 63
– Install the big end cap, using guide pin
- 35 - or - 36 -; see Fig. 64.
– Attach the upper part of the conrod, in-
sert the big end bolts and tighten them
to the specified torque.
Note:
The groove (63/1) in the big end cap must
be on the side nearest to the injection
pump. The groove (63/2) in the main
conrod must be on the valve tappet side.
64
L / M . . 09.96 3
M 06.00 Piston and cylinder
M 06.10 Air-cooled engines
- 12 - 16 - 17 -
Preparations:
– Detach the cylinder head; see M 07.00.
Dismantling:
– Mark the relative position of the cylinder
and piston and pull off the cylinder.
– Take out the piston pin circlip;
see Fig. 65.
– Press the piston pin out by hand and lift
off the piston.
65
– Check the cylinder wall for seizure
marks or score-marks. Checking cylinder wear and suitability
– Check that the dimensions of the for further use:
cylinder are correct; for values, see – Repeat the piston ring measuring pro-
Section 4. cedure with a new piston ring.
– Check the piston for seizure marks or – Compare the measurements obtained in
ring web fractures. this way with the maximum wear limits;
– Check piston ring end gaps; for values, if these are exceeded, the cylinder
see Section 4. should not be re-used but an oversize
cylinder should be installed instead.
Checking piston ring end gaps:
– If the measured values are within the
–Pull the piston rings off the piston.
limits, the cylinder can be used again,
– Place each piston ring in its cylinder
with new piston rings.
bore and move it to the TDC position of
In this case, the cylinder wall must be
the piston.
roughened very slightly with a honing tool,
– Clean the piston crown and use it to po-
since the honed finish will have been lar-
sition the piston ring at a right-angle to
gely worn after a lengthy period of opera-
the cylinder axis.
tion. If the cylinder were to be used again
– Use feeler gauges to measure the
without re-honing (whether the existing
piston ring end gap (where the ends of
piston rings or new ones were fitted), ex-
the piston ring come together).
cessive oil consumption would
– For limit values, see Section 4.
occur and would not drop to the normal
level after a time, since the piston rings
would not be able to match themselves
to the cylinder wall.
3 L / M . . 09.96
Procedure:
– While turning the honing tool in the
cylinder, it must also be axially moved
back and forth. Recommended speed of
rotation approx. 350 rpm.
– Depending on the speed, the tool
should perform about 20 - 30 strokes a
minute. This stroke rate will produce a
cross-cut pattern at approximately 45°.
– Continue honing only until this crosscut
pattern can be clearly seen. It is nor-
mally obtained after a honing time of
approx. 20 - 45 seconds per cylinder.
– After honing, clean the cylinder with
warm or hot water and a cold cleanser,
using a brush, then oil the cylinder wall.
Attention !
Do not hone for too long period, and do
not dry-hone.
Use honing oil or a mixture of oil and fuel
(1:1).
If possible, keep below the speed stated
above. Wear protective goggles!
Assembling:
To install the piston, follow the dismantling
instructions in the reverse order.
Note:
The recess in the piston crown must be
located towards the injection pump; 66
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
install the cylinder; see Fig. 67.
67
L / M . . 09.96 3
M 06.00 Piston and cylinder
M 06.20 Water-cooled engines (H.L 30)
- 16 - 17 -
Preparations:
– Take off the cylinder head; see M 07.00.
– Take off the alternator and water pump.
Dismantling:
– Carefully pull the cylinder off.
– Take out the piston pin circlip;
see Fig. 68.
– Press the piston pin out by hand and lift
off the piston.
– Examine the cylinder for seizure marks
or score-marks on the cylinder wall.
– Check cylinder dimensions and state of
wear; see Section 4.
– Inspect piston for seizure marks and
ring web breakage.
– Check piston ring end gap;
see Section 4.
– Check piston ring end gap, cylinder 68
wear and suitability for further use;
see Section 4.
3 L / M . . 09.96
Installing:
Install the piston by following the removal
procedure in the reverse order as appro-
priate.
Note:
The recess in the piston crown must be
located towards the injection pump; see
Fig. 69.
– The piston ring gaps must be offset by

120° in each case; oil the rings well in
their grooves.
For each cylinder bore a figure is stam- 69
ped on the crankcase and another figu-
re on the cylinder. The two figures, if ad-
ded together, represent the thickness of
the shim plates to be inserted at the ba-
se 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 cylin-

der and crankcase manufacturing toleran-
ces; in addition the gap is reduced to
within a tolerance range of 1.0 - 1.5 mm.
– Attach shim plates 70/1 to the cylinder

with a small amount of grease.
– Oil the cylinder bore well.
Note:
If spare parts are obtained, the manufac-
turer attaches the shim plates to the
crankcase or cylinder. They are not inclu-
ded in the set of gaskets. 70
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 . . 09.96 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
piston; see Fig. 71.
– With the help of a second person, care-

fully place the cylinder assembly in 71
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 back
and forth until the pistons enter the cy-
linders.
– Take off the piston ring clamping tools
and move the centre piston back and
forth during the lowering movement until
it enters its cylinder.
– The ring clamping strap is pushed into
the cylinder, and can then be pulled out
of the rectangular side opening in the
crankcase with the aid of a strong piece
of wire.
72
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.
3 L / M . . 09.96
M 07.00 Cylinder head
M 07.10 Air-cooled engines
–
Preparations:
– Take off the enclosure hood.
– Take off the exhaust-side enclosure and
the muffler (silencer); see A 03.00.
– Unscrew and remove the air outlet
shaft, side panel and cross-member;
see M 35.00.
– Unscrew and remove the cover plate
and take out the screws for the base
plate; see M 35.00.
– Take off the air cleaner.
– Remove the injector; see M 14.00.
Dismantling:
– Take off the cylinder-head (rocker) 73
cover.
– Unscrew the shouldered nuts (73/1) and
bolts (73/2).
– Pull off the centering flanges (73/3).
– Detach the support plate mounts.
– Press the air guide housing and suction
shaft apart.
– Lift off the support plate; see Fig. 74.
– Detach the exhaust manifold and air in-
take pipe.
Note:
To simplify dismantling of the air intake pi-
pe, it is best to unscrew and remove the
air cleaner (74/1).
– Lift off the cylinder head and remove

the pushrod protective tubes.
Checking the cylinder head:

– Inspect for cracked webs or worn valve
tapers.
– Check the radius of the rocker pads for
wear. 74
L / M . . 09.96 3
Installing:
– Determine the gap between the cylinder
head and the piston at TDC.
Note:
This gap should be re-measured when
ever a cylinder, piston, conrod, crankshaft
or crankcase is renewed. Measure at all
cylinders, with cold engine.
– Clamp the cylinder down with a suitable

tensioning strap, and use a depth gau-
ge; see Fig. 75. 75
– Turn the engine over until the piston

reaches and passes through top dead
centre (TDC).
– Measurement „a“ plus the thickness of
b S a
gasket „b“ yields the gap dimension „S“
stated in Section 4; see Fig. 76.
76
3 L / M . . 09.96
– Having established the correct gasket
thickness, coat it with a little grease on
the cylinder head side, and place it in
the centering collar on the cylinder
head.
Note:
Centering on the L 30 is not by means of
a centering collar but with centering slee-
ves; 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) du-
ring 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 . . 09.96 3
– Screw the cylinder head on until it is re-
sting evenly on the cylinder, but without
final tightening.
– Align the cylinder head by attaching the
exhaust manifold; see Fig. 80.
– Install the support plate and the injector
centering flanges.
– Tighten the cylinder head uniformly, in a
cross-wise pattern, to the specified tor-
que.
– Take off the exhaust manifold, attach
the gaskets and install it again.
– Adjust valve clearances to the specified
values. 80
– Further installation work is as described
for removal, but in the reverse order.
3 L / M . . 09.96
M 07.20 Overhauling cylinder head (air-cooled engines)
-1-2-6-7-
Preparations:
– Removing cylinder head - see M 07.10.
Dismantling cylinder head:
– Place the cylinder head on the cente-
ring collar.
Note:
On the L 30, pull out the centering slee-
ves (81/1).
The cylinder head sealing face must not
be scratched or otherwise damaged; al-
ways use a soft cloth or similar underlay.
– Remove circlip (81/2) and pull off
rockers with shims (81/3).
– Press spring plate (81/4) down with tool
- 6 - and remove the valve spring collets
(81/5).
– Take out the valve springs with underlay
washers (81/6) and lift off the rocker
housing (81/7).
– Lift off the intermediate plate (81/8) and
take out the valve cone.
Checking parts:
– Check the valve guides and valve stems
for score marks and correct dimensions;
– Inspect the cylinder head for cracks (in
the metal webs) or an uneven sealing 81
surface.
– Renew the O-ring seals (81/9); on the
L 30, seal them with silicone.
– Check the valve seat rings and valve
cones for wear; for valve recess into
cylinder head, see Section 4.
– Check correct dimensions of rocker
bushing, rocker shaft and rocker pad
radius; for values, see Section 4.
L / M . . 09.96 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
complied with; for projection,
see section 4.
82
– Using a hand-held reamer - 2 -, ream

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

seat milling cutter; see Fig. 84.
Note:
The valve seat must always be re-machi-
ned after installing new valve guides or
before installing new valves, but no more
metal than absolutely necessary (no pat-
ches anywhere on circumference of valve
seat).
84
3 L / M . . 09.96
– 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 ex-
haust ports. No fuel should seep through
the valve seats.
Assembling the cylinder head:
– To assemble the cylinder head, follow
the dismantling instructions in reverse as
appropriate.
Note:
– Engines built in 1979 - 1983 have one
spring per valve; from 1984 onwards,
two springs per valve were installed. If
repair work is carried out in this area,
the second valve spring should be retro-
fitted.
– On M 31/M 40 engines up to 2300 rpm,
cylinder heads with the code letter „H“
(high swirl) are used; above 2300 rpm
the cylinder head code letter is „L“ (low
swirl).These code letters are stamped in
the inlet port.
– On engines built from mid-1986 on with
a running speed below 2300 rpm the
longitudinally slotted rocker and valve
stem seal adjusting screws are used;
these screws were installed on all engi-
nes from mid-1989 onwards. Retrofit
these screws if repairs are carried out.
– Before pressing on the valve stem seals,
insert the valves into the valve guides.
Press the seals on with assembly tool
- 7 -.
L / M . . 09.96 3
M 07.30 Water-cooled engines (H.L 30)
–
Preparations:
– Drain the coolant and unscrew the coo-
lant lines from the cylinder head.
– Take off the exhaust system and ex-
haust manifold.
– Take off the air cleaner and detach the
air intake flange.
– Remove the injectors.
Dismantling:
– Take off the cylinder head cover; Fig. 85.
– Slacken off the shouldered nuts by half a 85
turn (85/4) in the reverse order shown in
Fig. 86 or 87.
– Unscrew and remove the nuts in the
same order. Unscrew the hex nuts (85/5)
with spring washers (85/6) and take off
the rocker pedestals.
– Lift off the cylinder head.
– Take off the pushrods and protective
tubes.
– Take off the cylinder head gasket and
sealing rings.
Checking the cylinder head:
– Visual inspection for cracks in webs.
– Visual inspection of cylinder head sea-
86
ling face for unevenness.
– Check pad radius on rockers for wear.
87
3 L / M . . 09.96
Assembling:
– Clean the sealing faces on the cylinder
head and cylinder.
Clean the cylinder.
– Install a new cylinder head gasket (88/1)
and sealing rings (88/2).
– Insert the protective tubes (88/3) with
springs (88/4), thrust rings (88/5) and
new sealing rings (88/6) into the bore in
the crankcase. Grease the sealing rings
slightly.
– With the aid of a second person, place
the cylinder head in position, making
sure that the protective tubes with O-ring
seals enter the holes in the cylinder
head correctly.
– Insert the pushrods.
– Install the rocker pedestals. Make sure
that the adjusting screws are inserted
correctly into the pushrods; if necessary,
unscrew them.
– Coat the thread of the tierod in the oil 88
cavity with sealant D.
– Screw on the shouldered nuts and tigh-
ten them by hand in the order 1 - 15
(Fig. 86 or 87) until they are 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 alu-
minium pushrods is 0.40 mm, for engines
with steel pushrods 0.20 mm.
– Further installation is by following the re-

moval instructions in the reverse order.
L / M . . 09.96 3
M 07.40 Reconditioning the cylinder head (water-cooled engines)
-1-2-6-7-
Preparations:
– Remove the cylinder head; see M 07.30.
Dismantling the cylinder head:
– Remove the circlips (89/10) from the
rocker pedestal and pull off the rocker
(89/11) with shim washers (89/12).
– Pull out the centering sleeves (89/1) and
place the cylinder head on its sealing
surface.
Note:
Do not scratch or otherwise damage the
cylinder head sealing face; always place a
soft cloth or similar underlay beneath it.
– Press the spring plate (89/2) down with

tool - 6 - and remove the valve spring
collets (89/3).
– Take out the valve springs (89/4) with
underlay washers (89/6).
Note:
Engines with a running speed of less than 89
2300 rpm are equipped with adjusting
screws with longitudinal slots for the
rockers (89/13) and valve stem seals
(89/5).
You are recommended to retrofit these
screws during subsequent repair work.
Engines built up to and including 1983 (all
running speeds) have single valve springs.
During repairs you are recommended to
install double valve springs on engines
which run at more than 2300 rpm.
– Place the cylinder head on the exhaust
side and pull out valve cones (89/16
and 17).
– Take off cover (89/7) with sealing ring
(89/8) and take out thermostat (89/9).
3 L / M . . 09.96
Checking parts:
– Check correct dimensions of bushing
for rocker (89/14), rocker shaft (89/15)
and rocker pad radius. For values, see
Section 4.
– Check valve guides and valve stems for
wear; see Section 4.
– Inspect the cylinder head for cracks (in
webs) and unevenness of the sealing
surface.
– Examine the valve seat rings and valve
collets for wear. Note valve recess in
head; see Fig. 90 and Section 4.
Reconditioning cylinder head: 90
– If necessary, press the valve guides out
with pressing-in tool - 1 -, Fig. 91.
– Press in new valve guides with the
same tool - 1 -.
Note:
The pressing-in depth must be correct; for
projection, see Fig. 92.
– Ream out the valve guides to nominal

diameter with hand-held reamer - 2 -,
Fig. 91.
– If the valve seats are leaking or have
been damaged locally, or after installing
new valve guides, they must be rema-
chined. This is carried out with special
milling cutters which are available com- 91
mercially.
– Only mill away sufficient metal to elimi-
nate patches on the surface of the valve
seat.
– After this, lap in the valves (with grin-
ding paste, grain size 180 - 250);
see Fig. 91.
92
L / M . . 09.96 3
Note:
– To check the lapped valve seats, clean
and install the valves, then pour a small
quantity of diesel oil into the inlet and
exhaust ports.
No diesel oil should seep through past
the valve seats.
– Note correct valve recess measurement;
see Fig. 90 and Section 4.
Assembling cylinder head:
The cylinder head is assembled by follo-
wing the removal procedure in the reverse
order.
Before pressing on the valve stem seals,

insert the valves into the valve guides.
Press the seals on with assembly tool - 7 -.
3 L / M . . 09.96
M 10.00 Oil pump
- 13 -
Preparations:
– Take off the timing case cover; see M
11.00.
Dismantling:
– Take out the machine screws (97/1) and
lift off the oil pump.
– If necessary, pull out needle roller bea-
ring (98/1) with an internal puller.
Checking / repairs:
– Examine the contact face for the shaft
sealing ring for score-marks.
If the contact face is worn, a „wear
sleeve“ can be pushed over it. Use sea-
lant E for this purpose.
Installation instructions are included with
the spare part.
Assembly:
– Using a plastic-faced hammer, drive the 97
needle roller bearing flush into the
crankcase.
– Insert the oil pump with bearing journal
into the needle roller bearing and place
it over the centering sleeves.
– Insert and tighten the machine screws.
Note:
– Apply sealant D to the machine screw
for hole (98/2).
– Coat the endface of the oil pump which
is in contact with the crankcase with
sealant B.
– Re-assemble the engine in the reverse
order for dismantling.
– When renewing the oil pump, make sure
that the correct type is installed (2- / 3-
or 4-cylinder engine).
98
L / M . . 09.96 3
Checking oil pressure:
– Unscrew the oil pressure sensing switch
and connect an oil pressure gauge with
flexible hose - 13 - .
– Install the side panel and hood to
enclosure.
– Start the engine and compare the oil
pressure when it is at regular operating
temperature with the values in Section
4; see Fig. 99.
– Before assembly, coat the thread of the
oil pressure sensing switch with sealant
D.
99
3 L / M . . 09.96
M 11.00 Timing cover
–
Preparations:
– Take off the exhaust silencer (muffler);
see A 03.00.
– Take off the air guide housing;
see M 35.00 (engines with enclosure
only)
– Take off the fan; see M 13.00.
– Take off the engine shutdown device;
see M 20.00.
Dismantling
Timing cover without hydraulic pump
drive: 100
– Pull the hose off the crankcase breather
valve (100/1).
Note:
From 2 L 40.14, 3/4 L 40.13, M 41 and on
the M 31, M 40 and M 41 the hose con-
nection (101/2) for the crankcase breather
has been moved to the top of the crankca-
se. The valve (101/1) was bonded into the
air intake pipe until early 1987. Since then
it has been secured in the air intake pipe
by two O-rings.
– Remove the circlip (102/1) and coil
spring (102/2) from the pull rod of the
engine shutdown device.
From early 1996 an additional cup 101
spring and an O-ring have been installed
to seal the pull rod.
– Unscrew and remove the belt pulley
(102/3) and the machine screws holding
the timing cover.
– Pull off the timing cover and remove the
gasket.
Checking parts:
– Check the timing cover for cracks or un-
evenness of the sealing surface.
– Examine the shaft sealing ring for dama-
ge and renew if necessary.
– Press off the breather valve cap and
examine the diaphragm for damage.
102
L / M . . 09.96 3
Dismantling
Timing cover for hydraulic pump drive:
Additional work:
– Take off the hydraulic lines and hydrau-
lic pump.
– Pull out the driver (103/1).
– Remove both machine screws (103/2)
including spring washer (103/3), plate
(103/4) and gasket (103/5).
– After removing the timing cover retai-
ning screws (103/4) and taking off the
timing cover (103/6) the support mount
(103/9) is exposed and can be taken off
after removing the two screws (103/7) 103
with spring washer (103/8).
Note:
– On older L 30/L 40 / H.L 30 engines
there is no support mount for the hy-
draulic pump drive.
– H2L30 and H3L30 engines do not have
a hydraulic belt tensioner. For this rea-
son the pull rod is locked out of action
by a hoop. A blank cover is fitted in
place of the shutdown device; see
Fig. 104.
Assembling:
– Apply grease to the contact edge of the
shaft sealing ring.
– Before fitting, coat new seals on both
sides with sealant H. 104
– Install the timing cover.
– On the 2 and 3 L ... insert M 8 x 12
machine screws into holes (105/1) and
(105/2) with sealant D.
105
3 L / M . . 09.96
– Further timing cover attachment and en-
gine assembly procedures are as descri-
bed for removal, but working in the re-
verse order.
Note:
When renewing the breather valve, secure
the new valve housing in the insert (105/3)
with sealant E and then seal all around
with sealant H.
If the insert is renewed, use sealant C for
bonding in.
The hose spigot opening in the air intake
pipe must face toward the intake port of
cylinder 1.
The position of the opening can be varied
by inserting or removing spacing washers
(only on engines with crankcase breather
in timing cover).
L / M . . 09.96 3
M 12.00 Extra-fuel device
M 12.10 with injection pump PFR 1K 80
–
Preparations:
– Detach the enclosure hood and side
panel; see M 35.00.
– On 2-cylinder engines, detach the oil fil-
ler pipe.
Dismantling:
– Remove the screws for the extra-fuel
device and take it off; see Fig. 106.
Dismantling the hydraulic extra-fuel
device:
– Take off the circlip (106/1), unscrew the
threaded pin (106/2) and push out cylin-
der (107/1).
– Take off the circlip (107/2) and pull out
the end cover (107/3) and the piston
(107/4) with spring (107/5).
– Take out circlip (107/6) with spring plate
(107/7), spring (107/8) and ball (107/9).
Inspection / repair: 106
– 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
device:
– Assembly is as shown in Fig. 107,
working in the reverse order of
dismantling.
107
3 L / M . . 09.96
Checking the extra-fuel device:
– After assembly, check free movement
of the extra-fuel device's piston by pul-
ling it out and letting it slide back; see
Fig. 108.
Attaching:
– The extra-fuel device is installed by fol-
lowing 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 108
is noted. Apply sealant H to both sides
of the gasket. Only a thin coat should
be applied, so that the oily in the extra-
fuel device is not blocked. Install the
machine screws with sealant D.
Adjusting the extra-fuel device:
– Piston (107/4) also acts as the full-load
stop for the governor lever and is
eccentrically located in the cylinder
(107/1).
The effective stroke and, therefore, the

maximum injected fuel volume are
adjusted by turning this cylinder.
For effective stroke requirements and ad-
justing 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 109
setting of the volume limiting eccentric
was not altered.
L / M . . 09.96 3
- 34 -
Preparations:
– see M 12.10.
Dismantling:
– Pull terminal 7 off the solenoid valve
(only version with electric engine shut-
down).
– Remove the screw (111/28) with sealing
rings (111/36).
– Make a scribed mark on the crankcase
and the monitoring block, so that the
monitoring block can later be re-atta- 110
ched in the same position as before,
and the original power setting is there-
fore retained.
– Take out the retaining screws (111/5)
and take off the engine monitoring
block.
Dismantling the engine monitoring
block:
– Unscrew and remove the cover (111/9)
with sealing ring (111/10); on version
with electric engine shutdown, unscrew
the solenoid valve (110/21) and take it
off complete with sealing ring (110/23),
armature (110/24) and spring (110/25).
– Remove the screw plug(111/8).
– Take off the lock washer (111/26), pull
up shaft (111/12) take out lever
(111/15), drive out locking collet
(111/14) and remove shaft (111/12)
from the housing.
– Remove circlip (111/22); hold eccentric
(111/21), slacken off grub screw
111
(111/17) and pull out the eccentric with
springs (111/20,25) and piston (111/18).
3 L / M . . 09.96
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 reverse order of work
for removal.
Note:
To install the piston, use auxiliary bushing
- 34 -.
Assembly:
– Move the speed control lever to the
„Stop“ position.
– To attach, follow the instructions for de-
taching the device in the reverse order.
– Make sure that the gasket is correctly
seated and note the scribed mark which
indicates the correct position; install the
machine screws with sealant D.
Note:
When attaching, make sure that lever
(112/1) engages to the left of plate
(112/2). To do this on engines with the lo-
wer idle speed governed to ≥ 1700 rpm
the shaft (111/12) must be turned coun-
ter-clockwise when assembling. Check
when the monitoring block is installed by
turning shaft (111/12) counter-clockwise;
it must then move back by itself to its initi-
al position.
Adjusting the engine monitoring block:
– The maximum fuel injection volume is
112
adjusted by turning the piston (111/18).
For adjusting the fuel injection volume
and the correct procedure see section
M 14.00. If the same monitoring block is
detached and re-attached, the fuel in-
jection volume does not need to be ad-
justed, provided that the setting of
piston (111/18) was not altered.
If the monitoring block is renewed or after
it has been repaired, the fuel injection vo-
lume (power setting) must always be
adjusted.
L / M . . 09.96 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 -
Preparations:
– see M 12.10.
Dismantling:
– Detach plug connector (164/1) from
engine wiring harness (electric version
only).
detach cover (164/4) and solenoid valve
(164/5) with gasket (164/6)
– Make a scriber mark on the crankcase
and the servo block to ensure that they 164
are installed again in the same relative
positions and the power setting there-
fore remains unchanged.
– Remove machine screws (164/2) and
take off the servo block.
– Turn lever (165/1) in the „Start“ direc-
tion. Shaft (165/2) is then turned by
locking pin (165/3) and the sickle-pat-
tern lever (165/4) moved to the starting
position.
When the lever is released, all elements
must return to the „Stop“ position
(Fig. 166).
Ensure free movement if necessary by 165
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 relea-
sed.
166
3 L / M . . 09.96
Dismantling the servo block:
– Take off lock washer (164/7)
– Hold piston (164/8), raise shaft (164/9)
and take out sickle-shaped lever
(164/10).
– Release piston (164/8) carefully and
take it out of the housing.
– Drive out locking collet (164/11) and pull
shaft (164/9) out of the housing.
– Take out grub screw (164/12).
– Remove circlip (164/13) and take out
washer (164/14) and eccentric disc
(164/15).
Inspection / repair: 167
– Examine piston to wear score marks.
– Renew gaskets. Attention!
Assembling the servo block: The sickle-shaped lever must never be
– Assemble in the reverse order of work under or to the right of the stop.
for removal. – Screw the block on tightly.
When installing the piston, use bushing – Set the speed control to the „Start“ po-
- 34 -. sition and move piston (167/8) back and
Note correct position of gasket (164/6) forth between the start and stop posi-
(oil hole). tions. With the injection pump removed
Apply sealant D to machine screws or the side cover taken off, the governor
(164/3) and tighten them to a torque of lever can be seen to perform the same
6.5 Nm. movement.
Attention:
If the tightening torque is too high, the
servo piston may seize (distortion).
Assembling:
– 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 posi-
tions; attach a lead seal.
L / M . . 09.96 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 approx.
6 mm.
F » 15 - 20 N (loading can easily be
overcome with the finger), free passage
between bores 3 and 4.
– Apply the electric current to connection 168
„3“ (green wire):
the valve pin must extend fully.
F » 30 - 50 N (very difficult to overcome
loading with finger pressure), free pas-
sage between bores 3 and 4.
– If any repairs are made to the wiring,
make sure that the plugs are wired up
correctly (Fig. 169).
Note:
When installing the valve solenoid or
cover (164/4), note the corrct installed
position (this also applies to the gasket);
holes 168/3 and 5 must be aligned.
169
3 L / M . . 09.96
M 13.00 Fan
–
Preparations:
– Take off the exhaust-system enclosure
(engines with enclosure only) and the
silencer (muffler); see A 03.00.
– Take off the enclosure side panel, air
outlet duct, air guide housing and fan
impeller; see M 35.00.
Non-encapsulated engines:
– Take off the cooling air guide.
– Take off the hydraulic shutdown device;
see M 20.00.
– Disconnect the battery.
Removing:
– Mark and disconnect the wiring at the
alternator.
– Take out screws (117/1).
– Pull out the fan housing.
117
Checking parts:
– Check the fan housing sealing strips for
signs of damage; if necessary, attach
new sealing strips with adhesive G.
Installing:
– Apply a slip agent, e.g. Vaseline, to the
contact faces of the fan housing sealing
strips.
– Install the fan housing and check that
the sealing strips are correctly positio-
ned.
– Re-assemble the items removed from
the engine in the reverse order of work
for their removal.
– Make sure that the Poly-V belt is instal-
led accurately.
Note:
When connecting cables to the alternator, 118
do not accidentally interchange them; see
Fig. 118.
L / M . . 09.96 3
M 14.00 Fuel injection equipment
M 14.00 Injection pump, functional check
-5-
Preparations:
– Take off the capsule hood and side
panel.
– Detach the fuel delivery pipes from all
injector pumps, holding the pipe union
to prevent it from turning.
Check injection pumps:
(Fig. 182)
– Attach test nozzle - 5 - with delivery
pipe to the injection pump you wish to
check.
– Cover the pressure valve holders on the
other injection pumps with absorbent
cleaning cloths.
start position and run the starter.
If the spray pattern is correct, the pump

you have checked is in good mechanical
working order (no pump element wear, no 182
leakage at pressure valve).
ATTENTION !
Keep hands away from the injected fuel
spray.
The fuel spray from the injector nozzle
can cause blood poisoning if it contacts
the skin.
3 L / M . . 09.96
–
Preparations: – Unscrew and remove the extended stub

– Take off enclosure hood, side panel bolt or machine screw (119/2) at the in-
and cover for air guide housing; jection pump for cylinder 1 this also acts
see M 35.00. as a travel limiter for the governor rod.
– Take off fuel filter and fuel delivery Note:
pump. This device is not fitted to older engines.
– Take off guide plate for oil cooler on – Disconnect tension spring (120/1) at the
S/Z. governor rod (120/2) and pull out the
– To remove pump for cylinder No. 1 on governor rod guide (120/3) with packing
engines with shutdown solenoid, take seals.
off the starting charge device including
the solenoid (see A 11.00); on the two-
cylinder engine also take off the oil filler
pipe.
Removing the injection pump:
– Set the speed control lever to a central
position.
– Remove the hex nuts for the injection
pump mounting and pull out the injec-
tion pump.
– Take off the shim washers.
Note:
– Do not install the shim washers at the
wrong points.
– On four-cylinder engines, the hollow
119
restrictor screw for the injection pump
at the timing end has a return-flow
restrictor.
During repairs, make sure that the cor-
rect hollow screw is used or else the
volume of fuel in the injection pump will
be altered.
Removing the governor rod:
– Take off the oil filler pipe, the starting
charge control device and all side co-
vers.
– Using water pump pliers, press out
locking pin (119/1) until the governor
lever can be moved to the flywheel end;
see Fig. 119.
120
L / M . . 09.96 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
taken off.
Checking parts:
– Check the governor rod for score-marks
in the governor rod guide area.
Installing the governor rod:
– Install the governor rod by following the
instructions for its removal in the rever-
se order.
– After installing the governor rod, secure 122
its guide in position with the side cover:
see Fig. 123.
Note:
Clearance at the governor rod guide
between crankcase and cover must not
exceed 0.1 mm.
If clearance is greater than this, insert
packing seals between the crankcase and
the governor rod guide.
123
3 L / M . . 09.96
– Using the speed control lever, locate the
governor rod so that the groove for the
toothed rack pin on the flywheel-end in-
jection pump is precisely in the centre
of the mounting hole for the injection
pump in the crankcase; see Fig. 124.
– Check the position of the other grooves
and if necessary reposition the sliding
elements on the governor rod.
– Insert the injection pumps and tighten
them in position.
– For adjusting work, see M 14.50.
Note: 124
When installing the injection pumps, use
the shim washers at the points from which
they were previously removed. The figure
stamped next to the injection pump indi-
cates the thickness of the shims,
e.g. 75 = 0.75 mm.
L / M . . 09.96 3
-27 -
Preparations:
– see M 14.10.
Removing the injection pump:
– Insert locating pin - 27 - into the hollow-
drilled stud bolt of pump 1 to lock the
governor rod in the „X“-Position (141/1).
– Remove the hex nuts and spring was-
hers securing the injection pump.
– Pull out the injection pump.
– Take off the paper gaskets and shim
washer.
141
Note:
The installed positions of the gaskets,
shim washers and injection pumps must
not be changed, or else the start of fuel
injection will be altered.
Removing and installing governor rod:
– Pull out locking collet (170/5).
– Remove the roller guide at the flywheel
end (paper washers 170/3 are used to
compensate for play); note the presence
of spring (170/4).
– Pull the governor rod out towards the
flywheel.
– Install in the reverse order of work.
170
Note:
When installing the governor rod, the stop
pin for the governor rod (126/2) must en-
gage between the governor lever (126/1)
and the leaf spring (126/3).
126
3 L / M . . 09.96
Installing the injection pump:
– Connect the governor rod in the „X“-po-
sition.
– When installing the injection pumps,
use the same shim washers and ga-
skets as before.
– Insert the injection pumps and, before
tightening, press them towards the
cylinder and position them so that the
scribed mark on the pump flange is
precisely aligned with the correspon-
ding notch on the crankcase (127/1).
Note:
When installing a new injection pump, 127
add up the figures on the pump flange
and the crankcase. The total of the two
figures is the thickness of the shim
washers with gaskets to be inserted, in
tenths of a millimetre. Never use more
than one steel shim washer. How to make
up the seal pack:
Total 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 . . 09.96 3
M 14.30 Injector
- 4 - 37 -
Preparations:
– Take off the enclosure hood and side
panel; see M 35.00.
Removing:
– Unscrew and remove fuel pressure pipe
(128/1) and oil leak-off line (128/2).
128
– Unscrew and remove loop for injector

(128/3). Take out the injector and sea-
ling ring (129/1) using impact extractor
tool - 4 -.
Functional check:
– Connect extension tube with test pres-
sure 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.
ATTENTION !:
Keep the hands away from the fuel spray
emerging from the injectors.
The fuel spray from the injectors can
cause blood poisoning. 129
3 L / M . . 09.96
– Check the spray pattern of the injector
Assembling:
– Install the injectors using new sealing
rings and working in the reverse order
for their removal.
Note:
– Place the seal on the injector so that
the soft graphited side is at the top
towards the injector.
– Tighten the hex nuts to retain the injec-
tor and the collar nuts on the pressure
pipe to the specified torques (see Sec- 130
tion 4), holding the pressure pipe con-
nection 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 . . 09.96 3
M 14.40 Injector nozzle
–
Preparations:
– Remove the injector; see M 14.30.
Dismantling:
– Take off the collar nut (132/1) and remo-
ve the nozzle with needle (132/2). 7
– Take out spacer (132/3), pressure pin
(132/4), spring (132/5) and shim
washers (132/6). 6
Checking parts:
– Inspect the needle of the nozzle for 5
score-marks or signs of overheating.
– The nozzle needle (132/2a) must, when 4
the nozzle is held vertical, slide down
slowly and smoothly under its own 3
weight on to its seat.
– Renew the nozzle if necessary.
2a
– Check the sealing faces on the nozzle
holder for damage.
2
Assembling:
– Install the shim washers, spring, pres-
sure pin and spacer in the nozzle holder
again as shown in Fig. 132, in the oppo- 1
site order from their removal.
– Attach the injector nozzle so that the
pins on the spacer locate in the holes
on the nozzle.
132
– Screw on the collar nut and tighten it.
– Mount the injector on the tester and
determine its fuel delivery pressure; for
values, see Section 4.
– Correct the fuel delivery pressure by in-
serting shim washers:
Thicker washers = higher delivery
pressure
Thinner washers = lower delivery
pressure 0.15 mm » 15 bar.
3 L / M . . 09.96
M 14.50 Adjustment work with PFR 1K 80 injection pump
(up to 2 L 40.16, 3-4 L 40.15, M 40.12, also L 30 and H.L 30)
- 10 - 11 - 29 -
Adjustments
Kind of repair needed Notes
Removing and installing resp. Install shims again at the point

exchanging complete injec- where they were removed
tion pump
Synchronising
Injection pump must only be re-
Repairing injection pump paired by authorised workshop
Renewing camshaft for Start of injection

injection pump Measure effective stroke before
Synchronising removal and restore when
Renewing crankcase installing
Effective stroke
Removing and installing Synchronising
governor rod
Synchronising Measure effective stroke before
Renewing governor rod Effective stroke removal and restore when
installing
Measure effective stroke before
Renewing starting charge Effective stroke removal and restore when
control installing
Conversion from injection-
pump with control lip at top Start of injection All pumps on the engine must be
(start of series production) converted
to pump with control lip at Synchronising
bottom (current series For adjustment data see
production status) Effective stroke Section 4
Modifying the power setting Effective stroke Measure the original effective-
stroke. Alter effective stroke only
by difference value
L / M . . 09.96 3
1. Adjusting start of fuel delivery:
Note:
Start the adjustment at the timing-end
injection pump.
– Move the speed control lever to the full-

load position and secure it there.
– Remove the pressure tube connection
and pressure valve at the injection
pump.
– Screw the overflow device - 10 - into the
injection pump.
– Screw the extension pin of the overflow
device into the dial gauge - 11 - and
insert it in the overflow device; see
Fig. 133.
– Connect the fuel feed line from the test
tank.
Note:
The test tank must be attached at least 133
200 mm (8 in) above the injection pump.
– Turn the crankshaft in the normal direc-

tion of rotation (counter-clockwise when
looking at the flywheel), until the dial
gauge needle starts to move.
– Open the fuel feed; fuel will emerge
from the overflow device.
– To turn the engine over, attach a ratchet
with 1/2-inch square end to the square
recess in the belt pulley.
– Continue to turn the engine over slowly
until the fuel emerges from the overflow
pipe slowly as separate droplets
(approx.. 1 droplet every 5 - 6 seconds).
– This point is the start of fuel delivery.
3 L / M . . 09.96
– Read the angle in degrees at the in-
spection hole in the connecting housing,
and compare it with the desired value in
Section 4. To take the reading, remove
the plastic plug: see Fig. 134.
On engines without a connecting
housing, the fixed mark is stamped on
the crankcase.
Note:
On engines built before or in 1980, the
angle in degrees is only stamped on the
engine for the first (timing-end) cylinder;
only two marks are provided for the other
cylinders. The short mark (half diameter 134
of inspection hole) shows the angle for
the start of delivery, the long mark (full
diameter of inspection hole) shows the
piston top dead centre point.
– If necessary, correct the start of fuel de-

livery as follows:
If the reading is smaller than the
desired value:
= fuel delivery starts too late.
Remove shims.
If the reading is larger than the desired
value:
= fuel delivery starts too soon.
Add more shims.
Note:
Use a dial gauge as follows to determine
the thickness of the shims needed to cor-
rect the value:
– Set the dial gauge to „0“ at the actual

start of fuel delivery, and turn the fly-
wheel to the desired start of fuel
delivery.
The dial gauge will now show the thik-
kness of the shims to be inserted or re-
moved.
– Repeat the measurement procedure;
the fuel drip from the overflow pipe on
the adjusting device must start precisely
when the desired value is reached.
– Carry out the measuring procedure at
all injection pumps.
L / M . . 09.96 3
2. Adjusting end of fuel delivery: Note for engines from serial number
Note: L 30.17, 2 L 40.15, 3 / 4 L 40.14, M 40.11
Engines equipped with Type PFR 1K 80A on:
439/2 injection pumps must be adjusted
to the correct end of the delivery stroke. The governor rod travel limit screw
– Measuring procedure same as adjusting (135/2) must be unscrewed during this
start of delivery. work, or else the „Stop“ point for the
– Turn the crankshaft in the normal direc- pump governor rods will not be reached.
tion of engine rotation until the gauge
needle begins to move and the fuel
emerging from the overflow pipe starts
to drip slowly or ceases to drip.
– Continue to turn the crankshaft slowly
until the fuel just begins to drip from the
overflow pipe again (approx. 1 droplet
every 5 - 6 seconds).
– This point is the end of fuel delivery.
– The value obtained in this way must
agree with the desired value stated in
Section 4.
– If necessary, correct it as described
above.
3. Synchronising injection pump
delivery volume:
– Move the governor rod by hand fully to
the right, to the „Stop“ position, and
hold it there.
– Loosen all sliding elements (135/1) on
the governor rod; the toothed rack on
the flywheel-side injection pump must
be in the „Stop“ position.
– Move the sliding elements for the other
injection pumps to the right („Stop“ posi-
tion) until the pump toothed rack is
against its stop, and tighten there; see
Fig. 135.
– Release the governor rod.
– Before installing, coat the gaskets for
the cover and the starting charge device
on both sides with sealant H.
Apply the sealant only as a very thin
coating to the starting charge device, to
ensure that its oilway is not blocked
when assembling.
– Coat all bolt threads for the cover and
starting charge device with sealant D.
135
3 L / M . . 09.96
4. Adjusting effective stroke:
(on engines with start of delivery
adjustment)
– Install the start charging device and
replace the cover by hydraulic starting
charge adjuster 619 845 00;
see Fig. 136/3.
– Set the speed control lever to full load
and secure it there.
– Insert the overflow device with dial
gauge, as described in the section
„Adjusting start of fuel delivery“.
– Connect the fuel feed line from the test
tank and open the shutoff tap; fuel will
emerge from overflow device.
– Turn the crankshaft until the injection
pump has just reached the start of fuel
delivery (approx. 1 droplet of fuel emer-
ges every 5 - 6 seconds).
– Set the dial gauge to zero and continue
to turn the crankshaft in the normal di-
rection of engine rotation until the dial 136
gauge moves from „0“ to precisely the
nominal effective stroke value stated on
the type plate.
– In this position, fuel should start to drip
out of the overflow device again.
– If this is not the case, loosen grub
screw (136/2) and turn the eccentric
flow limiter (136/1) until the fuel begins
to drip out slowly.
– When the setting is correct, retighten
grub screw (136/2), seal it with lacquer
and install the cover again in place of
the adjuster (136/3).
L / M . . 09.96 3
5. Adjusting the effective stroke
(on engines with end-of-delivery
adjustment):
– Prepare for the adjustment in the same

way as described for start-of-delivery
adjustment.
– Set the injection pump to the end of fuel
delivery.
– Turn the crankshaft in the opposite
direction to normal rotation until the dial
gauge shows the nominal effective
stroke stated on the type plate.
– If necessary correct as described
above. For 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 con-
nection and tighten to the specified tor-
que. 137
6. Note on changing the power setting:

– Measure and make a note of the original power setting. Remember that as a result of
tolerances the actual effective stroke setting may not coincide exactly with the effecti-
ve stroke value on the type plate.
– The effective stroke setting for the desired power is obtained from the original effecti-
ve stroke setting plus (for an increase in power) or minus (for a decrease in power)
the difference between the two effective stroke values according to the adjustment
data.
Example:
To change an L 30 engine from power output B to power output F:
Effective stroke for power output F acc. table: 1,14 mm

– Effective stroke for power output B acc. table 1,07 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
3 L / M . . 09.96
M 14.60 Adjustment work with PFR 1K 90 injection pumps
(from engine serial numbers 2 L 40.17, 3-4 L 40.16, M 40.13
on L 31 / 41 and M 31 / 41: all engines)
- 23 - 24 - 25 - 26 - 27 - 28 -
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
Varying injected volume for nominal power output.
engine 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 . . 09.96 3
1. Crankcase mark for adjusting start
of fuel delivery:
– Insert measuring device - 25 - into the

calibrating device - 26 - and adjust it so
that both needles of the dial gauge are
at „0“; see Fig. 138.
– Insert the measuring device into the
mounting hole on the injection pump
and screw it down firmly. The correct
cam must be on its base circle.
– Turn the flywheel in the normal direction
of engine rotation until the start-of-deli- 138
very mark on the flywheel (15° before
TDC) for the cylinder in question is alig-
ned with the fixed mark on the crank-
case or in the inspection 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
mounting hole.
140
3 L / M . . 09.96
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 governor rod in position „X“
(141/1).
– Insert the marking device - 23 - into the

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

nominal power output
(engine stopped)

„Stop“ position.
– Remove the screw plug from the moni-
toring block housing or replace the val-
ve solenoid by the plate of the adjusting
tool -28-, then use a depth gauge to
measure the distance „S“ from the outer
edge to the flat face on the piston insi- 142
de; see Fig. 143.
– Screw in the injection volume adjusting
tool - 28 -, using a number of cooper
sealing 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 . . 09.96 3
– Remove the second injection pump
(looking from the timing end) and install
measuring device - 24 - in its place (the
ball end on the vertical lever must enga-
ge 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.
starting position.
– Insert locating pin - 27 - into the hollow-
drilled stud bolt, then turn the adjusting
screw slowly clockwise until the locating 144
pin engages under light pressure in the
corresponding slot of the governor rod;
Figs. 141 and 145.
This determines the „X“ position of the
governor rod.
– In this position, set the dial gauge scale
on the adjusting device precisely to „0“.
– Pull out the locating pin; the needle of
the dial gauge should then move by
0.01 - 0.02 mm.
– Determine the governor rod travel
stated on the type plate (the figure is in
hundredths of a millimetre).
– Turn the injection volume adjusting tool
until the dial gauge shows the control
distance needed. Do not forget the
0.01 - 0.02 mm already indicated by the 145
dial gauge.
Note:
A minus value (= lower power range) is
obtained by turning the adjusting tool
clockwise, a plus value (higher power) by
turning counter-clockwise.
– Tighten the grub screw (146/1) carefully

to prevent this setting from being lost,
and secure it with lacquer.
146
3 L / M . . 09.96
– Replace the adjusting tool - 28 - by the screw plug again, using a suitable tool (e.g.
screwdriver) to check that the engine monitoring piston slides smoothly. If it tends to
stick, slightly reduce the preload at the grub screw (146/1) and repeat the check.
– Remove the adjusting device - 24 - and install the injection pump (M 14.20).
Note on changing the power setting
Adjustment data for a change in engine power can be obtained from your HATZ service
point. Proceed as follows to change the power setting:
– Move the speed control lever to the stop position.
– Screw in the injection volume adjusting tool - 28 -.
– Move the speed control lever to the start position.
– Install measuring device - 24 - and set the dial gauge to precisely „0“.
– The governor rod travel for the desired power output is obtained from the original
governor rod travel setting plus (for increased power) or minus (for decreased power)
the difference from the adjustment data.
Example:
To change a 3 M 40 engine (n=3000 rpm) from power output B to power output F.
Governor rod travel for output F acc. to adjustment data: +0.13 mm
Governor rod travel for output B acc. to adjustment data: -0.26 mm
Difference from adjustment values: 0.39 mm
The adjusting tool - 28 - must therefore be turned counter-clockwise until the dial gauge
of the measuring device - 24 - reads 0.39 mm.
If the engine's running speed is to be altered (with or without a change in power output),
the following work is needed:
– Set the engine speed to the new value.
– Move the governor rod to position „X“ and set the dial gauge to „0“.
– Turn the adjusting tool - 28 - until the dial gauge shows the governor rod travel called
for according to the type plate or adjustment data.
4. Adjusting the damping spring (generator operation, PV 187)
This adjustment can only take place with the engine running at the upper idle speed
limit and off-load. In addition, the engine must have reached its regular operating tem-
perature, or else the speed setting will not be accurate.
– Turn the stop screw for the upper idle speed limit (146/2) until this speed is approx.
0.3 % lower than the desired value according to the type plate.
Example:
Type plate data 3000/60 = 3060 - 0.3 % = 3050 rpm. Make sure that the 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 approx. 0.3 %.
L / M . . 09.96 3
M 17.00 Schwungrad
–
Dismantling:
– Remove bolts (148/3) and disc (148/2).
– Screw in two suitable stud bolts to act
as guides.
– Take off the flywheel.
Assembling:
– Drive locking collet (148/1) into the end
of the crankshaft at the flywheel end to
provide the necessary centering action.
– Attach the flywheel so that the locking
collet enters the centering hole.
– Place the disc (148/2) in position, insert 148
the bolts (148/3) and tighten them to the
specified torque.
3 L / M . . 09.96
M 20.00 Engine shutdown device / belt tensioner
- 20 - 21 - 39 -
Preparations:
– Take off the cover for the air guide
housing and front impeller.
Non-encapsulated engines
– Take off belt guard, if fitted.
Removing:
– Press back the tensioning roller and at-
tach the locking device - 36 - (Fig. 149).
– Take out screws (150/3) with spring
washers and remove the drive pulley
(150/4)(the drive pulley is not fitted from 150
year of manufacture 1985 onwards).
– Pull the belt pulley (150/5) out of its
centering mount and take it off together
with the Poly-V belt.
– Detach the oil line (150/1) and remove
the 3 machine screws (150/2) with
spring washers.
– Detach the fixation (150/7) at the coo-
ling fan, noting the installed shims.
– Take off the engine shutdown device
(150/6).149
L / M . . 09.96 3
Dismantling of engine shutdown
device: (from engine serial numbers
L 30.15, 2 L 40.12, 3/4 L 40.11).
– Remove the locking device.
Attention:
The piston with tensioning roller 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 ten- 151
sioning roller (151/6) back slightly
against its spring loading.
– Carefully release the spring loading
completely and pull out the piston
(152/3) with spring (152/6) and filler
(152/7).Remove the support disc
(152/2) and quad ring (152/4) from the
housing.
– Take the restrictor screw (153/1) out of
the back of the housing.
– Press the shaft out of the piston and
remove the tensioning roller. 31
– Take off the Nilos rings (151/8). Drive
the ball bearings (151/9) out towards 174
the outside in each case, since a circlip
(151/10) is installed between them.
– Take out the support disc (151/11).
Checking the parts:
– Check the piston for the tensioning rol-
ler and the bushings in the housing for
score- or wear-marks. If damaged, re-
new the bushings or the piston.
To renew the bushings, use special
tools - 20 - 21 - and press the bushings
in as shown in Fig. 174.
– Check the tensioning roller ball bearing
and renew if necessary.
– Renew quad rings (152/4) and (152/5).
– Renew the tensioning roller or belt pul-
ley if any grooves are damaged or ribs
broken off.
– Check that the bore in the restrictor
screw is not blocked.
152
3 L / M . . 09.96
Assembling:
– Assembly by following the dismantling
procedure in the reverse order.
– Make sure that the Poly-V belt is fitted
correctly.
Assembly instructions:
– Insert restrictor screw (153/1) with
sealant D.
– Pack the Nilos rings (151/8) with anti-
friction bearing grease when assem-
bling.
Note for older versions of L 30 / L 40
engines:
– The circlip (152/1), support washer
(152/2) and quad rings (152/4) and
(152/5) have been installed since 1980.
– A ball pressure-relief valve was installed
instead of the restrictor screw (153/1)
until about early 1982.
153
– A modified tensioning roller bearing is
used from the L 30.15 / 2 L 40.12,
3/4 L 40.11 onwards.
L / M . . 09.96 3
M 22.00 Air cleaner
–
Dismantling:
L - engines
– Take off the enclosure hood.
– Remove dirt adhering in the air cleaner
housing area.
1
– Loosen screws (175/1) only sufficiently
to permit the complete air cleaner hou-
sing to be raised.
– Cover the opening in the intake pipe to
prevent dirt or other foreign bodies from
entering.
– Open the air cleaner housing and take
out the filter element (176/3).On three- 175
cylinder engines, the cover (176/2) is
also held with a clip (176/7).
M - engines
– Release the clips (177/1) and take off
the air cleaner housing cover (177/2)
– Remove dirt adhering in the region of
the air cleaner housing.
– Slacken off screws (177/3) only enough
to permit the cover (177/4) with filter
element (177/7) to be raised.
– Cover the opening in the suction pipe to
prevent dirt and other foreign bodies
from entering.
– Check the sealing faces for signs of 176
damage.
– Clean the filter housing and the cover.
Spacer „5“ is connected by an elastic 1 2
sleeve „6“ with the retaining screw, so that
it cannot fall into the intake pipe during
maintenance work.
3
– If the spacer is loose, renew bushing
3 4
„6“. 6
7 5
5
Assembling:
– Follow the instructions in the reverse
order.
L3/58
177
3 L / M . . 09.96
M 31.00 Crankcase breather
–
General:
The crankcase breather operates by way 5
of a diaphragm valve in the intake pipe.
During maintenance or repair work, in
particular if the engine's oil consumption
is high or it is producing too much blue
exhaust smoke, you are recommend to 1
check the condition of the diaphragm.
Dismantling:
– Pull housing 1 with cap 2 and dia-
phragm 3 out of the intake manifold and
3
hose 4 (Fig. 178). 4
– Pull cap 2 out of housing 1 and remove 2
diaphragm 3.
– Examine the diaphragm for cracks and
renew if necessary.
– Renew O-rings 5.
Assembling: 178
– Proceed in the opposite order to that
described above.
L / M . . 09.96 3
M 32.00 Speed control
M 32.10 Engines with PFR 1K 80 injection pump
–
Preparations:
– Detach the enclosure hood.
– Take off the speed control lever and the
side panel; see M 35.00.
– Renew the oil cleaner.
– On two-cylinder engines, unscrew and
remove the oil filler pipe; see M 12.00.
Dismantling:
– Remove machine screws (154/1).
– Turn the speed control shaft counter- 154
clockwise to the „Stop“ position and pull
the governor rod towards the flywheel
end; see Fig. 155.
– As shown in Fig. (155/1), move the
governor lever over to the timing side
and pull it out downwards.
Dismantling the speed control:

– Pull out the cotter pin or locking collet
(156/1) and push out the bolt (156/2).
– Drive out the locking collet (156/3), pull
off the torsion spring (156/4) and sleeve
(156/5), drive out locking collet (156/6) 155
and pull off the speed control fork
(156/7).
– Unscrew the tensioning plate (156/8)
and remove circlip (156/10), support
washer (156/11) and shim(s) (156/12).
– Pull off governor shaft stop (156/13),
remove circlip (156/14) with spacing
washer (156/15) and pull out shaft
(156/9).
156
3 L / M . . 09.96
– Check ball bearing at governor lever for
wear.
– Check governor lever, pin for speed
control, fork, adjusting shaft and hou-
sing for score-marks; renew parts if
damaged.
Assembling:
– Push in the shaft and install the spacing
washer, circlip, governor shaft stop,
shim(s), support disc, circlip and tensio-
ning plate. Push on the fork (157/3) and
drive the locking collet (157/4) in flush
with the fork; see Fig. 157. 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 con-
nect to the locking collet.
– Further assembly is in the reverse order
for dismantling; use a new gasket.
– Apply sealant D to screws (154/1) when
inserting.
158
L / M . . 09.96 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-clock-
wise to the „Stop“ position and pull the
governor rod towards the flywheel end
of the engine; see Fig. 179.
– Turn speed control mount (179/1) to the
right and pass governor lever (179/2)
under governor rod (179/3).
– Carefully pull the speed control mount
out downwards.
154
Dismantling the speed control:
(Fig. 180)
– Drive out locking collet 1.
– Slide out pin 2 and take off governor
lever 3.
– Take out locking collet 4 for stop 5 and
pull out control shaft 6.
– Disconnect spring 7.
– Drive out locking pin 8 and pull off fork
9.
– Check ball bearing at governor lever for
wear.
– Check governor lever, speed control pin,
fork, control shaft and housing for score 179
marks and renew all damaged parts.
180
3 L / M . . 09.96
Assembling:
– Drive in locking collet (181/1) until it
projects by 10.5 mm.
– Insert spring (181/2) into fork (181/3)
and push on to control shaft.
– Drive locking collet (181/4) in flush with
the fork and connect the spring to it by
using a suitable tool.
– Continue installation by following the re-
moval instructions in the reverse order.
Note:
Since there are various patterns of gover- 181
nor lever, make sure when repairing the
speed control that the original governor
lever is installed again.
If the governor lever or the complete
speed control is renewed, note that torque
equalisation may have been activated at
the original governor lever.
In case of doubt, contact your nearest
HATZ service point.
L / M . . 09.96 3
M 35.00 Capsule
Preparations:
– Remove the engine.
Note:
Normally it is only necessary to remove
the engine from the equipment in which it
is being used in order to dismantle the
enclosure if the air guide housing or rear
panel have to be taken off.
– Remove exhaust enclosure;
see A 03.00.
Dismantling:
– Take off the hood (159/1), speed control
lever (159/2), side panel (159/3) and
cover plate (159/4).
159
– Detach the air outlet shaft (160/1) and

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

injectors and raise the engine slightly at
its suspension lug until the baseplate of
the enclosure can be unscrewed and
removed.
– Detach the feet from the engine.
– When the feet have been removed, the
four 22 mm hex bolts used to attach the
baseplate should be used to support
the engine.
160
3 L / M . . 09.96
– Unscrew the earth (ground) strap and
the + line from the rear panel of the
enclosure.
– Take off the rear panel with intake duct;
see Fig. 161.
161
– Unscrew the cover from the air guide

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

– Examine the various sections of the en-
closure for damage.
– Renew damaged or incomplete sealing
strips.
162
Assembling:
– Assemble the enclosure by following the
dismantling instructions in the reverse
order as appropriate.
Note:
Make sure that all enclosure sections are
carefully installed and that all sealing
strips are seated correctly. Unless the en-
closure is completely sealed, neither the
potential level of noise reduction nor ade-
quate cooling can be ensured.
163
L / M . . 09.96 3
4. Tables
L / M . . / 07.96 4
Tightening torques for threaded connections
General requirements in Nm:
Nm ÷ 9.81(10) = kpm
Nm ÷ 1.3558 = lb ft
Screw strength rating

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 . . / 07.96
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

(Coat the tierod thread and washer contact face in the
oil cavity with sealant D) 50 65
Big end bolts: M 10 x 1 (8 mm Allen screw) 60 60

M 11 x 1 (10 mm Allen screw) – 115
Machine screws for counterweights 65 65
Machine screws for end cover, flywheel side

(Coat thread with sealant D) 10 10
Hex nuts for securing injectors 15 15
Pressure valve at injection pump 35 35
Collar nut for injector nozzle 85 85

L 41. M 41 40-50
Machine screws at balancing weight

bearing journals (4-cyl.) 30 30
Machine screws at drive gearwheel for balancing weights

(4-cyl.)(Coat thread with sealant D) 75 75
Hex nut for attaching spring bridge (governor) 25 25
Machine screws M 12 x190 (crankcase halves) 90 90
Flywheel bolts 135 200
Machine screws for gearwheel on crankshaft 30 30
Machine screws M 6 for securing cam tracks

(injection timer) 14 14
Hex bolts for connecting housing

(Coat thread with sealant D) 140 140
Support mount for front engine feet (Silent Pack) 130 130
Hex bolts for governor weight holder 25 25
Hex nut for cylinder head cover (pressure-cast version) – 10
Machine screws holding solenoid valve

to engine monitoring block – 6.5
L / M . . / 07.96 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 - 1.1 1.0 - 1.5
Gasket at cylinder head mm 0.7 - 0.8 - 0.9 - 1.0 - 1.1 -1.2 1.2
Shim washers 1) mm – – – 0.1 - 0.2
Valve clearance, cold (20 ± 10°C) mm 0.10 0.10 0.10 0.40 2)
Valve stem ∅ mm 8.96 -0.015

Wear limit ∅ mm 8.85
Inlet valve head ∅ mm 43.1 -0.3 40.1 -0.3

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

min. mm 0.00 0.85 0.85 0.85
outer ∅ mm +0.046
15 +0.038
Valve guide
inner ∅ mm +0.009
9H6 0
Wear limit innen ∅ mm 9.05
Bore in cylinder head ∅ mm +0.006

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 . . / 07.96
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
Wear limit ∅ mm 18.90

+0.021
Bore in rocker ∅ mm 21 H 7
0
+0.046
Rocker bushing innen ∅ mm 19 -0.012
Wear limit innen ∅ mm 19.20
Radius at rocker mm 8
(no flats allowed)
Axial clearance of rocker mm 0.1 - 0.2

(insert shims only on
the circlip side)
L / M . . / 07.96 4
Repair data
Camshafts (injection pump drive and valve gear)
Camshaft bearing journal diameters
-0.060
Governor side and centre mm 54 e 6
-0.079
Wear limit mm 53.85

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

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

-0.007
Flywheel side 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
Axial clearance of camshaft mm 0.1
4 L / M . . / 07.96
Repair data
Balancing weights
Bearing point diameters – two- and three-cylinder engines
0
Balancing weight shaft mm 28 h 5 -0.009
Axial clearance – two-cylinder engines mm 0.15 - 0.6

– three-cyliner engines mm 0.15 - 0.7
Wear in the needle roller ∅ mm bis 27.97

bearing area
Bearing point diameters - four cylinder engines
-0.080
Bearing journals for balancing weights mm 44 d 6 -0.096
+0.018
Bearing bushing for balancing mm 44 +0.083
weights (pressed-in)
Endplay mm 0.15 - 0.4
L / M . . / 07.96 4
Repair data
.L 30 / H .L30 .L 31 / .M31 .L41/.M41.

.L 40 / .M40
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 ∅ mm 32.30 36.30 36.30
Max. misalignment.* mm 0.08 0.08 0.08
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 (1 µ = 1/1000 mm)
Piston
Normal ∅ mm 94.94 101.92 101.90
Oversize mm +1.0 +0.5 +1.0**
Clearance max. mm 0.07 0.09 0.11
Clearance min. mm 0.06 0.08 0.10
+0.009 +0.010
Piston pin bore ∅ mm 32 +0.004
36 +0.004
Wear limit mm 32.05 36.05 36.05

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

Piston ring endplay max. mm 0.2 0.2 0.2
* At 300 mm length: conrod must not be readjusted.

** These oversize-cylinders resp. pistons are no more available.
4 L / M . . / 07.96
Repair data
Piston rings
.L 30. H.L30
End gap mm:
Ring groove No. Designation Dimensions
normal max. 1)
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
II 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
normal max. 1)
Standard 102 x 93.4 x3
I Trapezoidal 0.40 - 0.65 1.2
102.5 x 93.9 x 3
Oversize
103 x 94.4 x 3*
Standard 102 x 93.4 x 2.5
Cutaway
II 0.40 - 0.65 2.5
micro-chamfer 102.5 x 93.9 x 2.5
Oversize
103 x 94.4 x 2.5*
Standard 102 x 93.4 x 4
III D-ring 0.30 - 0.60 2.5
102.5 x 93.9 x 4
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
I
repair work if they have worn to 60 % of the
limit value.
II
* These oversize piston rings are no longer
III available.
L / M . . / 07.96 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
Wear limit mm 59.88 63.88

Out-of-roundness max. mm 0.05 0.05
Conicity max mm 0.003 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 0
Centre bearing journal ∅ mm 72 h 6 -0.019 72 h 6 -0.019

Conicity max. mm 0.003 0.003
Width mm 32 +0.3 32 +0.3
Radius mm 3.5 -0.2 3.75 -0.2
0 0
Main bearing journal, ∅ mm 72 h 6 -0.019 72 h 6 -0.019
governor side
Width mm 26.5 -0.2 26.5 -0.2
Radius mm 3.5 -0.2 3.5 -0.2
0 0
Main bearing journal, ∅ mm 72 h 6 -0.019 72 h 6 -0.019
flywheel side
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 . . / 07.96
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 0.5

Hardness Rc 50 - 55 50 - 55
Hardening depth mm 2.5 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
∅ mm 59.5 +0.040 63.5 +0.040

Normal wall thickness mm 1.468 - 1.480 1.468 - 1.480
Undersize mm 1.718 - 1.730 1.718 - 1.730
Internal (installed) main bearing.

+0.099 +0.099
Normal ∅ mm 72 +0.056
72 +0.056

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

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

clearance after waer mm 0.3 0.3
L / M . . / 07.96 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
Engine type Injection pump HATZ Ident No. Start of 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 PFR 1 K 80 A 467 1)2) 501 407 00 before TDC
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 numbers: 2 L 40.17. 3 - 4 L 40.16. M 40.13. L 31. M 31. L 41. M 41
Engine type Injection pump HATZ Ident No. Start of delivery

L 31. M 31
PFR 1 K 90 A 498 502 630 00 15° before TDC
L 40. M 40
L 41. M 41 PFR 1 K 90 A 546 504 442 01 10° before TDC
Injectors
Injector nozzle
Engine type HATZ Ident No. Spray pressure
Bosch HATZ
L 30. H .L 30
L 31. M 31 401 209 01 DLLA 160 S 908 501 413 01 250 +8 bar
L 40. M 40
L 41. M 41 504 440 00 DSLA 150 P 645 504 441 00 230 +12 bar
4 L / M . . / 07.96
Governors
L 30. H .L 30
Governor spring Governor weight
Speed Application
Ident-No. Wire ∅ mm Ident-No.
≤ 2300 036 012 01 3.0
Normal operation
> 2300 035 744 01 3.2
1500 * 036 014 01 2.5 035 729 00
1800 * Generator 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 036 012 01 3.0
Normal operation
> 2300 035 744 01 3.2
1500 037 739 00 2.5* 035 729 00
1800 Generator drive 036 013 01 2.6
3000 035 744 01 3.2
* Identifiction: windings are slightly grounded at circumference.
L 31. M 31. L 40. M 40 with injection pumps PFR 1K 90A 498, L 41 and M 41
Speed Application
≤ 2300 036 012 01 3.0
Normal operation
> 2300 035 744 01 3.2
1500 038 670 00 2.3*
035 729 00
1500 036 014 01 2.5
Generator 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 . . / 07.96 4
Lubricating oil content and dipstick
Oil content Dipstick

Engine type Oil sump
l marking
2-cylinder engines with 7.5 C
.L.. C / Z without 4.5 A
with 8.5 C
.L.. S. M.. without 5.5 A
3-cylinder engines with 10.5 D
.L.. C / Z without 8.0 A
with 11.0 D
.L.. S. M.. without 8.5 A
4-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 approx. 0.2 - 0.5 litre.
In all cases fill to the „max“ mark on the dipstick.
4 L / M . . / 07.96
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 filter telltale light (maintenance switch)
H5 Belt break warning light
H6 Pre-heat monitor telltale light
H7 Fan monitor warning light
H8 Remote desplay: engine light
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)
P1 Operating hours counter
P2 Revolution counter
P3 Pressure gauge
L / M . . / 07.96 4
Key to circuit diagrams (DIN 40719)
Key Designation of electrical component

R1 Pre-heat plug
R2 Heating flange
R3 Line resistor for pre-heat system
R4 Resistor
R5 Line resistor with thermo-time switch
S1 Pre-heat start switch (5-position)
S2 Master switch
S3 Pre-heat/start switch (3-position)
S4 Start-stop-switch
S5 Switch for speed control
S6 Engine temperature switch
S7 Oil pressure switch
S8 Pressure switch for air-filter
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-presure shut-down valve
Z1 Suppressor choke
Z2 Suppressor capacitor
4 L / M . . / 07.96
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 filter 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 . . / 07.96 4
4
Circuit diagram 12 V - system with fault display
L / M . . / 07.96
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

30
15
50
19
A4
S1 30 86 17
58 50a 15 19 17 U30 U50 U15 V1 K2 15
P0123 W-2
87 85
H1 H4 H2 H3 S5
P, 0, 1 86 K3 30
30 Win GND Aus P2 n
V2 H6 H6
86 30 85 87
P1 h
K1 85 87a F1 8A
W-6 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
L / M . . / 07.96
4
4
Circuit diagram 12 V - system with automat. shut down and starter protection module
L / M . . / 07.96
1 2 3 4 5 6
30
15
50

19
A4
S1 30 86 17
58 50a 15 19 17 U30 U50 U15 V1 V1 V1 K2 W-2 15
P0123 87 85
X2 S5
H1 H4
P, 0, 1 50 K4 86 K3 30
15
30 Win GND Aus P2 n
V1 H6 H6
86 30 SE 31 87 85 87
P1 h
V1 F1 8A
K1 85 87a
W-6 V2
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
Circuit diagram 12 V - system with automat. shut down and time relay
1 2 3 4 5 6

30
15
50
19
S1 30 86 17
58 50a 15 19 17 V1 V1 V1 K2 W-1 15
P0123 K7 87 85
30 X2 S5
85 H1 H4
P, 0, 1 K1 50 K4 15 30 86 K3 30
15
30 86 87a 87 H6 H6 P2 n
V1 85 87
SE 31 87 50 31 87 P1 h
W-6 V1 F1 8A
V2
V1 4 L / M 31,40,41 only
X1 1 22 3 X1 2 17 4 5 X1 18 7 V2 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
L / M . . / 07.96
4
4
Circuit diagram 12 V - automatic start / stop with repeat start interlock and time relay
L / M . . / 07.96
1 2 3 4 5 6
30
15
50

19
S1 30 86 17
58 50a 15 19 17 86 30 V1 K5 15 30 K2 15
P0123 W-1
K1 87 85
H1 H4 S5
85 31 87
P, 0, 1 SE K4 86 K3 30
87 15
30 H6 H6 P2 n
S4 V1 K7 15 30
50 31 87 85 87
P1 h
W-6 V1 50 31 87 F1 8A
61 V2
30 31
K6 X1 4 L / M 31,40,41 only
X1 1 22 3 X1 2 17 4 5 X1 18 7 0 6 8 14
87 50e V2
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
Circuit diagram 24 V - system with fault display
1 2 3 4 5 6

30
15
50
19
S1 17
58 50a 15 19 17 V1 15
P0123 W-1
H1 H4 H2 H3 S5
P, 0, 1 86 K3 30
30 V2 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
R3 R2
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
L / M . . / 07.96
4
4
Circuit diagram 24 V - system with fault display and starter protection module
L / M . . / 07.96
1 2 3 4 5 6
30
15
50

19
A4
S1 17
58 50a 15 19 17 U30 U50 U15 V1 15
P0123 W-2
H1 H4 H2 H3 S5
P, 0, 1 86 K3 30
30 Win GND Aus P2 n
V2 H6
86 30 85 87
P1 h
K1 85 87a F1 8A
W-6 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
R3 R2
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
Circuit diagram 24 V - system with automat. shut down and starter protection module

1 2 3 4 5 6
30
15
50
19
A4
S1 17
58 50a 15 19 17 U30 U50 U15 V1 V1 V1
W-2 15
P0123
X2 S5
H1 H4
P, 0, 1 50 K4 86 K3 30
15
30 Win GND Aus P2 n
V1 H6
86 30 SE 31 87 85 87
P1 h
V1 F1 8A
K1 85 87a
W-6 V2
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
R3 R2
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
L / M . . / 07.96
4
4
Circuit diagram 24 V - system with automat. shut down and time relay
L / M . . / 07.96
1 2 3 4 5 6
30
15
50

19
S1 17
58 50a 15 19 17 V1 V1 V1
W-1 15
P0123 K7
30 X2 S5
85 H1 H4
P, 0, 1 K1 50 K4 15 30 86 K3 30
15
30 86 87a 87 H6 P2 n
V1 85 87
SE 31 87 50 31 87 P1 h
W-6 V1 F1 8A
V2
V1 4 L / M 31,40,41 only
X1 1 22 3 X1 2 17 4 5 X1 18 7 V2 X1 0 6 8 14
Instrument box
Engine
R3 R2
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
Circuit diagram 24 V - automatik start / stop with repeat start interlock and time relay
1 2 3 4 5 6

30
15
50
19
S1 17
58 50a 15 19 17 86 30 V1 K5 15 30 15
P0123 W-1
K1 S5
H1 H4 31 87
85 K4 K3
P, 0, 1 SE 86 30
87 15
30 H6 P2 n
S4 V1 K7 15 30
50 31 87 85 87
P1 h
W-6 V1 50 31 87 F1 8A
61 V2
30 31
K6 X1 4 L / M 31,40,41 only
X1 1 22 3 X1 2 17 4 5 X1 18 7 0 6 8 14
87 50e V2
Instrument box
Engine
R3 R2
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
L / M . . / 07.96
4
Trouble-shooting table for electrical system
Trouble-shooting at instrument box
Malfunction Cause Remedy
Starter remains engaged Pre-heat/starter switch sticks in Set pre-heat/starter immediately

although pre-heat/starter position 3 after starting and to 0 by force; if this is not possi-
switch was released. does not return automatically to ble, disconnect the battery at
position I. 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 light does Bulb has blown or contacts are Insert a new bulb, clean the
not come on when engine is corroded. contacts.
stopped and pre-heat/starter Battery is flat. Reacharge the battery.
switch is on.
Battery is defective (internal Renew the battery.
short-circuits or sulphatised).
Defective pre-heat/starter Eliminate contact resistance,
switch, poor connections, renew wiring, tighten loose
defective wiring, contact terminals, if necessary renew
resistance in charging current pre-heat/starter switch.
circuit or line to generator telltale
light.
Defective voltage regulator. Renew voltage regulator.
Short-circuit at exciter or Disconnect charge line B+ (to
positive 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 light V-belt loose at generator. Correct V-belt tension.

flickers.
Generator telltale light Poor earth (ground) connection Make a clean earth connection in
continues to glow, after in instrument box. the instrument box.
starting engine. Wiring error, e.g. generator tell- Check the line from the generator
tale light leads to oil pressure telltale light to the generator and
switch. correct the wiring if necessary.
4 L / M . . / 07.96
Trouble-shooting at the battery
Malfunction Indication Cause Remedy
Battery not recharged Terminal voltage drops Poor connections, Eliminate the open
or insufficiently even a short time after open circuit or contact circuit, clean the termi-
recharged resp. goes recharging to 7 V resistance in charging nals, tighten terminals
flat rapidly. despite a 12 V nominal circuit, short-circuit in if slack.
voltage (or 14 V if line.
nominal voltage is Battery defective, inter- Renew battery.
24 V). nal short-circuit.
Capacity of battery has Recharge battery at low
dropped severely, be- current (approx. 1/40 of
cause it was heavily nominal capacity in
discharged for a lengthy Amps) for about 50
period (greyish-white hours. (This is only
cell plates = „sulphati- possible if sulphate coa-
sed“). ting is not yet too
strong.)Otherwise:
renew the battery.
Battery poles connected Repair generator

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 regula- Renew the voltage

tor (e.g. overheated / regulator.
overladed).
Loose V-belt at Correct V-belt tension.
generator.
L / M . . / 07.96 4
Corroded terminal Inadequate current Sulphuric acid attacs Wash down terminals
clips. flow, white salt depo- metals (except lead). with hot soda lye (but this
sits. must not enter the bat-
tery!), rinse with cold
water and apply acid-resi-
stant grease.
Battery is Voltage at terminals Charging voltage too Check voltage regulator,

overcharged. is always above high. renew if necessary.
16.5 V with 12 V Capacity of chosen Install a battery of larger
nominal voltage (or battery is too small. capacity. As a temporary
above 33 V with 24 V measure, discharge the
nominal votage), spe- battery at intervals, e.g.
cific gravity of acid is by switching on an elec-
above 1.285 kg/l so trical consumer when the
that the battery boils. engine is not running.
Engine run continuous- Install a voltage regulator
ly (several days) with with a different characte-
very little electrical ristic (lower charge-end
consumption (e.g. as a voltag
boat engine).
Defect in voltage regu- Have the voltage regulator
lator or generator. and generator checked,
renew defective compo-
nents.
Acid is escaping from Acid level is too high. Siphon off excess acid.
the cell plugs.
Acid level is too low. Acid level less than Overloading or natural Add distilled water or
10 mm (0.4 in) below water loss by evapora- demineralised water.
top of cell plates. tion (particularly in
summer).
4 L / M . . / 07.96
Battery fails pre- Battery was discharged too Check ratings of battery and
maturely. often and too serverely. generator, if necessary fit a
special „Z“ or „HD“ battery.
Battery becomes too warm. Install it at a more favourable
point.
Excessive vibration. Install battery at a more
favourable point or use an
„Rf“ battery (shakeproof)
Battery is discharging sulpha- Charge the battery at a small
tes. current level (approx. 1/40 of
its norminal capacity in
Amps) for about 50 hours.
Failing this, renew the bat-
tery.
Battery acid is contaminated. Renew the battery.
Too little power Voltage drops Run the battery down. Recharge battery with a sui-
from battery. severely when table charger.
load is applied. Voltage regulator is defective, Renew voltage regulator on
so that charging voltage is generator.
too low.
Connecting terminals loose or Clean the terminal clips and
oxidised. apply acid-proof grease to
them, then retighten the ter-
minal clips.
Battery capacity is too small Install a larger battery and if
(too many consumers). necessary a larger generator.
Battery is going flat because Renew the battery.
of impurities in its acid.
Sulphate deposits from bat- Charge the battery for approx.
tery (white coating on plates). 50 hours at a low current.
Failing this, renew the bat-
tery.
Battery is exhausted, active Renew the battery.
substance has fallen out of
plates.
Acid level too low. Top up with distilled water.
L / M . . / 07.96 4
Rate of charge never Terminal voltage soon Fault in generator, volta- Repair or renew gene-
adequate. drops to 7 V after ge regulator or wiring rator and voltage regu-
recharging (12 V connections. lator. Connect wiring
nominal voltage) or to firmly.
14 V (24 V nominal
voltage). V-belt too loose. Corret tension or renew
V-belt
To many consumers Install battery and
connected or generator generator with similar
is too small. ratings.
4 L / M . . / 07.96
Trouble-shooting at the starting device
Starter motor Generator telltale light Poor connections (loose Check battery lead and
does not turn does not come on. or corroded), break in connections, clean
when pre-heat/start cable or short to earth battery poles and termi-
switch is operated. (ground). nals, make sure connec-
tions are clean.
Battery flat or defective. Recharge or renew
battery.
Telltale light grows Battery is flat. Recharge the battery.
slowly dimmer when
pre-heat/start switch
is operate
Telltale light burns Line between terminal 50 Repair the break or if
brightly. and starter switch or bet- necessary renew the
Bridge terminals 30 ween terminal 30 and starter switch.
and 50 briefly at the battery is interrupted or
starter motor, the starter switch is faulty.
starter then turns. Starter inhibit relay or Renew defective relay.
delaying relay defective.
Telltale light burns Starter pre-engagement Renew the starter motor
brightly. Terminal 30 is winding has burned out. and ensure a good con-
not connected to posi- nection between terminal
tive battery pole. 30 at the starter and the
positive battery post
(main starter line).
Telltale light burns Worn or dirty contacts Renew solenoid switch.
brightly, solenoid on solenoid switch.
switch is energised,
when solenoid switch
is bridged, starter
motor turns.
L / M . . / 07.96 4
Starter motor turns Lengthy operating Carbon brushes Renew brushes and brush
too slowly or can- period without mainte- sticking. holder guides.
not turn the engine nance or in tough Carbon brushes worn. Renew carbon brushes.
over. environmental condi-
Poor spring pressure, Renew springs.
tion.
carbon brushes not
making contact.
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 operating Battery is flat. Recharge the battery.
and is energized, period without mainte- Low current flow Clean battery terminals,
but engine does nance, electrical because of loose or tighten connections.
not turn or only system has been corroded connections.
turns jerkily. neglected.
Carbon brushes Renew carbon brushes and
sticking. brush holder guides.
Carbon brushes worn. Renew carbon brushes.
Commutator dirty. Clean commutator.
Commutator scored or Recondition or renew the
burnt. starter motor.
Armature or field win- Recondition or renew the
dings defective. starter motor.
Starter pinion Engine does not turn, Starter pinion or Renew starter pinion, recon-
does not engage or turns jerkily. helical thread dirty or dition starter motor.
or disengage. damaged.
Flywheel gear ring Remachine or renew gear
damaged. ring.
Solenoid switch Renew solenoid switch.
defective.
Return spring weak or Renew return spring.
broken.
4 L / M . . / 07.96
Starter motor Noise of rotation. Starter relay defective. Switch of engine manually
continues to run at once (set speed control
after switch was lever to „stop“ and discon-
released. nect battery). Consequential
damage: electronic compo-
nents 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: dio-
des in generator destroyed.
Attention!
Unless the above measu-
res are taken within 2-3
minutes, the starter motor
will burn out (overheating)
Diode in shutdown soleno- Renew solenoid.
id (lifting or servo electro-
magnet) is defective.
Engine does not Valve solenoid on moni- Check operation of valve
start or starts toring block is not opening. solenoid and renew if
reluctantly, alt- necessary.
hough the starter Pre-heat system is defecti- Check pre-heat circuit and
motor is turning ve (only significant at renew any defective parts.
strongly. temperatures below
-10 to -15°C.)
L / M . . / 07.96 4
Trouble-shooting at the pre-heat system
Spiral indiator element Short to earth (ground) in a pre- Renew the pre-heat plug.
(pre-heat monitor) glows heat plug, pre-heat element (fila-
brightly almost immedi- ment) is bent and shorting inside
ately. engine.
Broken pre-heat wires in a line Renew the line resistor.
resistor, winding shorted to an
earthed component.
Interruption of pre-glow Since the pre-heat monitor, pre- Use a test lamp or a voltmeter (with
device pre-heat monitor heat plug or heating flange (and the pre-heat system switched on)
does not burning. also the second pre-heat plug or to check all the pre-heat monitor
line resistor on 24 V systems) are connecions.
wired in series, the complete pre- Renew defective parts.
heat system is out of action if a
component fails.
4 L / M . . / 07.96
Trouble-shooting at the alternator
Generator telltale Line D+/61 has a short to earth. Renew the line or repair the short to
light does not go out earth.
as engine speed Voltage regulator on generator Renew voltage regulator.
increases. is defective.
Wiring connections interchan- Connect the wiring correctly.
ged at generator.
V-belt for generator is slipping Correct V-belt tension or renew V-
or broken. belt.
Defective rectifier on generator, Repair generator
dirty sliprings, short-circuit in
line DF or rotor winding.
Generator telltale light Generator is not sufficiently Install a bulb of higher rating, e.g. 2
does not go out at low excited by telltale light. A 2 Watt W -> 3 W.Warning: bulb ratin must
engine operating speed bulb is normally used in the not exceed 5 W (or pre-exciter circuit
(e.g. 1500 rpm) light. will be destroyed)
Generator telltale light Rate of charge too low, brief Short-term remedy: recharge battery
glows only dimly when engine operating periods (parti- with a suitable charger.Long-term
engine is stopped and cularly when a maintenance- remedy: use a battery with better
pre-heat/start switch is free, vibration-proof battery is charge characteristic.
operated, battery not used).
being charged, or char- Poor connections, open circuit, Repair the break, clean the battery
ging only at a low rate. contact resistance or short-cir- terminals, tighten loose clamps.
cuit in charging circuit.
Battery is defective, internal Renew battery.
short-circuit.
Battery capacity has dropped Recharge battery at low current for
severely through being left flat about 50 hours. (Only possible if
for a long time (sulphate depo- sulphate deposits are not too exten-
sits). sive); otherwise: renew battery.
Battery capacity is too large. Install a smaller battery or a larger
alternator.
Alternator is defective. Repair alternator.
Voltage regulator is defective. Renew voltage regulator.
Loose V-belt at alternator Correct V-belt tension.
L / M . . / 07.96 4
Trouble-shooting at the alternator

When engine is stop- Poor connections, contact resistance Eliminate contact resistance, clean
ped the generator in charge circuit or in the line to the terminals, tighten loose terminals.
telltale light burns generator telltale light.
brightly, but when Defective voltage regulator. Renew voltage regulator
engine is running.
Defective alternator. Have alternator repaired.
Generator telltale Generator telltale light bulb has install a new bulb. Clean the con-
light does not burn blown or contacts are corroded. tacts.
when engine is stop- Battery is flat. Recharge with a suitable charger.
ped 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, poor Eliminate contact resistance, renew
contacts. wiring, tighten loose terminals if
Defective wiring line resistance in necessry renew pre-heat/ start
charging circuit or line to generator switch.
telltale light.
Defective voltage regulator. Renew the voltage regulator.
Short-circuit in an alternator exciter Disconnect charging line B+ (to pre-
or positive diode. vent discharge at a standstill), repair
alternator .
Carbon brushes worn. Renew carbon brushes.
Corrosion deposites on sliprings, Have alternator repaired.
open circuit in exciter winding.
Generator telltale KV-belt at alternator is too slack. Tension V-belt correctly.
light flickers.
4 L / M . . / 07.96
Trouble-shooting at engine monitor and display

Sudden pressure drop in Leak in oil circuit. Check lines and seals, renew if
lubricating oil circuit. necessary.
Oil lost from damaged sump. Renew the oil sump.
Defective oil pump. Renew the oil pump.
Engine cannot be stopped Defective valve solenoid or fuel Examine parts and renew if
at valve solenoid or fuel shut-off valve. necessary.
shut-off valve. Defective diode between generator Check the circuit and renew the
telltale light and terminal 15 at diode if necessary.
pre-heat/start switch, or diode by-
passed.
Incorrect display, light Short to earth (ground) in wire or Check wiring and eliminate short
does not burn although a switch. to earth.
fault is present. Defective switch. Renew switch.
No display, display light Broken wire. Renew broken wire.
does not burn despite Defective switch or relay. Renew defective components..
malfunction.
Defective bulb. Renew the bulb.
Engine protection relay: see „Instrument box“
L / M . . / 07.96 4
Trouble-shooting at electromagnetic components
Electromagnet does Defective electromagnet (e.g. winding Renew electromagnet.

not switch off engine burned out).
or vary engine speed. No power supply or open circuit. Check the circuit.
Defective switch or relay. Renew defective component.
Decoupling diode between generator Check the circuit and install or
telltale light and terminal 15 is mis- renew decoupling diode as neces-
sing or defective (applies only to sary.
shut-down solenoid with alternator).
Malfunction or failure Freewheel diode parallel to solenoid Renew freewheel diode.
of other electrical or is defecive.
electronic compo-
nents.
Starter motor does not Defective diode in shut-down Renew solenois.
disengage. solenoid (lifting or servo solenoid).
4 L / M . . / 07.96

Workshop Manual: 2-4L30. H2-3L30. 2-4L31. 2-4L40. 2-4L41. 2-4M31. 2-4M40. 2-4M41

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Workshop Manual: 2-4L30. H2-3L30. 2-4L31. 2-4L40. 2-4L41. 2-4M31. 2-4M40. 2-4M41

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Workshop manual

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1. General 2. Additional equipment

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3. Basic engine equipment M 14.00 Fuel injection equipment

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Use only genuine HATZ spare parts in repair work.

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

1 Lub.-oil filling and dipstick 1 Cylinder head cover

Engine: H 2 L 30, Engine: H 2 L 30,

Type-No. 064 10 81 031814

Engine series no.:

Customer spec. list No. 1)

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

Type 2L30 H2L30 3L30 H3L30 4L30

Operating side 30° 30° 25° 25°

Type 2L31 2L40 3L31 3L40 4L31 4L40

Operating side 30° 30° 25° 25°

Type 2L41 3L41 4L41

Operating side 30° 30° 25° 25°

A = 502 230 01 Loctite Activator 500 ml

No. Ident-Nr. Code Item

No. Ident-Nr. Code Item

– Unscrew and remove the hex bolts 1

– Remove the machine screws (186/1) 1

– On the 2 - 3 L 40 from date of manufac-

– Pull the upper and lower sections of the

Check the parts:

A 04.10 Crank handle

A 04.10 Crank handle

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

The automatic decompressor has the

Dismantling the automatic decompres-

Check dimension „B“:

Checking dimension „A“:

A 04.70 Recoil starter

Detaching the recoil starter: (Fig. 190)

Assemble in reverse order as described

Detaching and dismantling:

Operational check with start release

– Prime the fuel delivery pump with the

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

A 05.40 Alternator (air-cooled engines)

When series production of Series L / M

When replacing a MARCHAL alternator

When installing a VALEO voltage

Removing block-pattern oil cooler:

Checking parts: 197

Retrofitting engine with oil cooler:

Installing the shutdown device:

described above was ruled out. 208

Checking operation of thermostat 202

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

– Unscrew and remove the machine

– Tighten the machine screws for the dri-

– Apply sealant D to the machine screws

– Invert the lower part of the crankcase.

– Unscrew splash plate (9/1) and take out

– Coat the bearing bushings (12/1) with

– Insert splash plate as shown in Fig. 14,

– Insert the balancing weight with circle

– Take out the two machine screws at