Hatz 2-4L30 Workshop Manual
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Hatz 2-4L30 Workshop Manual

Hatz diesel engine workshop manual
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Workshop manual
438 402 00 - 1.97 - 0.4 Printed in Germany
2-4L30.
H2-3L30.
2-4L31.
2-4L40.
2-4L41.
2-4M31.
2-4M40.
2-4M41.

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gigmai kamane
February 10, 2025

Hi,I have a hatz 2l41c genset which I bought from a scrape metal company .Unfortunatly i cant use it because al the wiring have been stripped off with no indication of terminal connection since the genset is a time worn one (2001) model. Thanks

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Summary of Contents for Hatz 2-4L30

  • Page 1 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...
  • Page 3 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)
  • Page 4 M 12.30 with injection pump adjusting values PFR 1K 90 Governors from serial No. L/M31.12, Lubricating oil contents and dipstick M40.16, 2L40.19, 3-4L40.18 Key to circuit diagrams and L/M41 HATZ wiring identification M 13.00 Fan Circuit diagrams Trouble-shooting table for the electrical system...
  • Page 5 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.
  • Page 7 1. General L / M . . 10.98...

  • Page 8: Engine Illustrations

    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...
  • Page 9 Engine illustrations 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...
  • Page 10 Engine illustrations 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...
  • Page 11 Engine illustrations 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...
  • Page 12 Engine type Year of production Engine version Fabrication-No. (continous) Customer spec. list No. 1) Customer-specification MOTORENFABRIK HATZ GMBH D-94099 RUHSTORF KENNZ. Output in kW 2) MOTOR / FABRIK NO. ABE / AUSF. Execution code 2) MADE IN GERMANY...
  • Page 13 Lubricating oil circuit 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.
  • Page 14 Technical data L 30 Type 2L30 H2L30 3L30 H3L30 4L30 Operating cycle 4-stroke Combustion system Direct injection Number of cylinders Bore / stroke mm 95 / 100 Displacement cm 1416 2124 2832 Compression ratio 18:1 Firing order, cyl.1:timing end 1-3-2 1-3-4-2 Direction of rotation anti-clockwise (looking at flywheel)
  • Page 15 Technical data L 31, M 31, L 40, M 40 Type 2L31 2L40 3L31 3L40 4L31 4L40 2M31 2M40 3M31 3M40 4M31 4M40 Operating cycle 4-stroke Combustion system Direct injection Number of cylinders Bore / stroke mm 102/90 102/105 102/90 102/105 102/90 102/105 Displacemen cm 1470...
  • Page 16 Technical data L 41, M 41 Type 2L41 3L41 4L41 2M41 3M41 4M41 Operating cycle 4-stroke Combustion Direct injection Number of cylinders Bore / stroke mm 102/105 102/105 102/105 Displacement cm 1716 2574 3432 Compression ratio 18,7:1 Firing order, cyl.1:timing end 1-3-2 1-3-4-2 Direction of rotation...
  • Page 17 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...
  • Page 18 Special tools and workshop equipment Series L / M engines Ident-Nr. Code Item Pressing-in drift ∅ 9 mm for valve guides 669 350 00 03.1.1 Reamer 9 H 6 for valve guide 612 110 00 03.1.2 Clamp for fuel line 668 383 00 01.1.2 Impact extractor with accessories...
  • Page 19 Special tools and workshop equipment Te stb ox kti on s- un d Re lai s-F un 87 a Injection - pump – + timing set L / M . . 10.98...
  • Page 20 Disassembly tools for cable plug 629 055 00 Explanation of classification: Example: 03. 1. 2 Manufacturer: 1 . . . Only available from HATZ 2 . . . Same item (or equivalent in function) available commercialy 1 . . . Absolutely essential Necessity: 2 .
  • Page 21 Special tools and workshop equipment 32 / 33 35 / 36 L / M . . 10.98...

  • Page 23: Additional Equipment

    2. Additional equipment L / M . . 09.96...
  • Page 24 A 01.00 Fuel A 01.40 Fuel delivery pump - 3 - General: – When installing the fuel delivery pump, make sure that the delivery and suction lines are connected correctly. Dismantling: – Disconnect fuel feed line with clamp - 3 -. –...
  • Page 25 A 03.00 Exhausts A 03.12 Removing and installing the silencer (muffler) enclosure(L 30, L 31, L 40, C/K) – Preparations: – Remove the hood from the enclosure and air outlet duct; see M 35.00. Detaching: – Take out hex bolts (184/1) and detach the connecting stub pipe with exhaust pipe (184/2).
  • Page 26 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...
  • Page 27 A 04.00 Start mechanical A 04.10 Crank handle – Version A 04.10.1 Standard crank handle: This handle can be replaced at any time by one with kick-back damping if this becomes necessary or is required by regulations. Attention ! There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn.
  • Page 28 A 04.00 Start mechanical A 04.10 Crank handle – Version A 04.10.2 Handle with kick-back damping: The version for M .. engines is marked A on its housing, and takes the place of the standard crank handle if required. Attention ! There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn.
  • Page 29 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.
  • Page 30 A 04.00 Start mechanical 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 kompr. 2 = Automatic decompressor switched on, engine compression is built up auto- matically after about 8 turns of the...
  • Page 31 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.
  • Page 32 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.
  • Page 33 A 04.00 Start mechanical 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.
  • Page 34 A 04.00 Start mechanical A 04.80 Start release device (L /M 31/40/41) – Preparations: – On C/K, take off hood at enclosure and side panel; see M 35.00. – On S/Z and M.., take off side panel and cooling air duct for lubricating oil cooler. Detaching and dismantling: –...
  • Page 35 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. –...
  • Page 36 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 –...
  • Page 37 – Take off the air guide plate. – Take off the Poly-V belt; see M 20.00. Removing: 193 (*HATZ-internal cable marking) – Detach the earth (ground) lead from the battery. – Disconnect the leads from the alternator and mark them (Fig. 193).
  • Page 38 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.
  • Page 39 A 07.00 Lubricating oil 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 the cooling air duct to the oil cooler. Removing block-pattern oil cooler: –...
  • Page 40 A 07.00 Lubricating oil 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). – Unscrew and remove the threaded sleeve (199/2). –...
  • Page 41 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.
  • Page 42 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 spring loading. – Insert solenoid adjusting gauge 621 471 00 (206/1) into the hole in the housing;...
  • Page 43 A 11.00 Automatic devices A 11.70 Temperature-controlled starting fuel volume control - 24 - 28 - Adjusting: – Screw in adjusting tool - 28 - and attach measuring device - 24 -. – Pull the speed control lever briefly to „Stop“...
  • Page 44 A 15.00 Housing A 15.20 Connecting housing – Assembling: – Drive locking collets (200/1) into the crankcase. – Attach the connecting housing, insert four M 14 x 1.5 mm hex bolts (200/2) with spring washer (200/3) and tighten to the specified torque. Note: Apply sealant D to the bolt above inspection hole (200/4), since this is a...
  • Page 45 A 30.00 Liquid cooling 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 washers 2 and take off the water pump.
  • Page 46 A 30.00 Liquid cooling A 30.40 Thermostat (H.L 30) – Preparations: – Drain the coolant (only needed if the upper edge of the radiator is higher than the thermostat). – Detach the coolant line from thermostat cover (202/3). Dismantling: – Take out retaining screws (202/1) with spring washers (2).
  • Page 47 3. Basic engine L / M . . 09.96...
  • Page 48 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.
  • Page 49 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.
  • Page 50 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...
  • Page 51 – 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). Inspection / repair: – Check the bearing journals and bus- hings for score-marks and incorrect dimensions;...
  • Page 52 – 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. – Insert splash plate as shown in Fig. 14, insert the lower machine screws (14/1) and tighten them.
  • Page 53 – 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.
  • Page 54 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;...
  • Page 55 – 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.
  • Page 56 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.
  • Page 57 – Unscrew and remove the hex bolts (22/1) at both sides. – The two halves of the crankcase are se- cured together with straight pins (23/1). Drive these back with a hammer and a suitable drift until they are flush with the sealing face.
  • Page 58 Inspection / repair: – Check all crankshaft bearing journals for score-marks and incorrect dimen- sions; for measured values, see Section 4. Measure in two planes offset through 90 degrees. – Check the shaft sealing ring contact face for score-marks. If the contact face is worn, a „wear sleeve“...
  • Page 59 – 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. –...
  • Page 60 – 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;...
  • Page 61 – Check crankshaft endplay with a depth gauge, Fig. 34, and compare it with the desired value stated in Section 4. – 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.
  • Page 62 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.
  • Page 63 – Remove the circlip and shim washers and pull off the ball bearing with a two- arm puller; see Fig. 40. – If the gearwheel or camshaft is rene- wed, use puller - 30 - with forcing-off screw - 31 - to pull the gearwheel off the camshaft;...
  • Page 64 – 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). – Install the camshaft, noting the correct positions of the marks, and insert circlip (44/1).
  • Page 65 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. –...
  • Page 66 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;...
  • Page 67 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) –...
  • Page 68 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. – 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;...
  • Page 69 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.
  • Page 70 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).
  • Page 71 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 -.
  • Page 72 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. –...
  • Page 73 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.
  • Page 74 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. –...
  • Page 75 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°...
  • Page 76 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. –...
  • Page 77 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.
  • Page 78 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;...
  • Page 79 – 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;...
  • Page 80 – 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.
  • Page 81 M 07.00 Cylinder head 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.
  • Page 82 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;...
  • Page 83 – 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.
  • Page 84 M 07.00 Cylinder head 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.
  • Page 85 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.
  • Page 86 M 07.00 Cylinder head 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).
  • Page 87 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.
  • Page 88 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.
  • Page 89 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.
  • Page 90 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;...
  • Page 91 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.
  • Page 92 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). –...
  • Page 93 – 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.
  • Page 94 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;...
  • Page 95 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.
  • Page 96 M 12.00 Extra-fuel device M 12.20 with injection pump PFR 1K 90 - 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).
  • Page 97 Checking parts: – Examine the piston for score marks or wear. – Check the valve seat (111/19) for wear. – Renew the O-rings. Assembling the engine monitoring block: – Proceed in the reverse order of work for removal. Note: To install the piston, use auxiliary bushing - 34 -.
  • Page 98 M 12.00 Extra-fuel device 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).
  • Page 99 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.
  • Page 100 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.
  • Page 101 M 13.00 Fan – Preparations: – Take off the exhaust-system enclosure (engines with enclosure only) and the silencer (muffler); see A 03.00. Encapsulated engines: – Take off the enclosure side panel, air outlet duct, air guide housing and fan impeller; see M 35.00. Non-encapsulated engines: –...
  • Page 102 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.
  • Page 103 M 14.00 Fuel injection equipment M 14.10 with injection pump PFR 1K 80 – – Unscrew and remove the extended stub Preparations: – 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.
  • Page 104 – 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.) –...
  • Page 105 – 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. –...
  • Page 106 M 14.00 Fuel injection equipment M 14.20 with injection pump PFR 1K 90 -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).
  • Page 107 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-...
  • Page 108 M 14.00 Fuel injection equipment 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). –...
  • Page 109 – Check the spray pattern of the injector as shown in Fig. 130. 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.
  • Page 110 M 14.00 Fuel injection equipment 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). – Take out spacer (132/3), pressure pin (132/4), spring (132/5) and shim washers (132/6).
  • Page 111 M 14.00 Fuel injection equipment M 14.50 Adjustment work with PFR 1K 80 injection pump (up to 2 L 40.16, 3-4 L 40.15, M 40.12, also L 30 and H.L 30) - 10 - 11 - 29 - Adjustments Kind of repair Notes needed Removing and installing resp.
  • Page 112 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.
  • Page 113 – 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.
  • Page 114 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 439/2 injection pumps must be adjusted to the correct end of the delivery stroke. The governor rod travel limit screw –...
  • Page 115 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.
  • Page 116 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.
  • Page 117 M 14.00 Fuel injection equipment M 14.60 Adjustment work with PFR 1K 90 injection pumps (from engine serial numbers 2 L 40.17, 3-4 L 40.16, M 40.13 on L 31 / 41 and M 31 / 41: all engines) - 23 - 24 - 25 - 26 - 27 - 28 - Inst.
  • Page 118 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. –...
  • Page 119 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;...
  • Page 120 – 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. –...
  • Page 121 – 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: –...
  • Page 122 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.
  • Page 123 M 20.00 Engine shutdown device / belt tensioner - 20 - 21 - 39 - Preparations: Encapsulated engines: – Take off the cover for the air guide housing and front impeller. Non-encapsulated engines – Take off belt guard, if fitted. Removing: –...
  • Page 124 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). –...
  • Page 125 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.
  • Page 126 M 22.00 Air cleaner – Dismantling: L - engines – Take off the enclosure hood. – Remove dirt adhering in the air cleaner housing area. – Loosen screws (175/1) only sufficiently to permit the complete air cleaner hou- sing to be raised. –...
  • Page 127 M 31.00 Crankcase breather – General: The crankcase breather operates by way of a diaphragm valve in the intake pipe. During maintenance or repair work, in particular if the engine's oil consumption is high or it is producing too much blue exhaust smoke, you are recommend to check the condition of the diaphragm.
  • Page 128 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;...
  • Page 129 Inspection / repair: – Check ball bearing at governor lever for wear. – Check governor lever, pin for speed control, fork, adjusting shaft and hou- sing for score-marks; renew parts if damaged. Assembling: – Push in the shaft and install the spacing washer, circlip, governor shaft stop, shim(s), support disc, circlip and tensio- ning plate.
  • Page 130 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;...
  • Page 131 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...
  • Page 132 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.
  • Page 133 – 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. – 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.
  • Page 135 4. Tables L / M . . / 07.96...
  • Page 136 Tightening torques for threaded connections General requirements in Nm: Nm ÷ 9.81(10) = kpm Nm ÷ 1.3558 = lb ft Screw strength rating Thread 10.9 12.9 M 10 M 12 M 14 M 16 M 18 M 20 M 22 L / M .
  • Page 137 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) Big end bolts: M 10 x 1 (8 mm Allen screw) M 11 x 1 (10 mm Allen screw)

  • Page 138: Repair Data

    Repair data Cylinder head L 41 L 31, M 31 L 30 H .L 30 M 41 L 40, M 40 0.85-0.95 1.0 - 1.1 1.0 - 1.1 1.0 - 1.5 Gasket at cylinder head 0.7 - 0.8 - 0.9 - 1.0 - 1.1 -1.2 Shim washers –...
  • Page 139 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 45.5 Wear limit 44.0 Length of outer valve spring, off-load 58.0 Wear limit 56.5 -0.020 Rocker shaft ∅...
  • Page 140 Repair data Camshafts (injection pump drive and valve gear) Camshaft bearing journal diameters -0.060 Governor side and centre 54 e 6 -0.079 Wear limit 53.85 +0.021 Flywheel side 20 m 6 +0.008 (ball bearing seat) Internal diameter of bearing bore in crankcase +0.030 +0.058 Governor side...
  • Page 141 Repair data Balancing weights Bearing point diameters – two- and three-cylinder engines Balancing weight shaft 28 h 5 -0.009 Axial clearance – two-cylinder engines 0.15 - 0.6 – three-cyliner engines 0.15 - 0.7 Wear in the needle roller ∅ mm bis 27.97 bearing area Bearing point diameters - four cylinder engines...
  • Page 142 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 39 H 6 bushing +0.019 +0.019 Big end bore ∅ mm 63 H 6 67 H 6 +0.085...
  • Page 143 Repair data Piston rings .L 30. H.L30 End gap mm: Ring groove No. Designation Dimensions normal max. Standard 95 x 87 x 3 Trapezoidal 0.40 - 0.65 Oversize 96 x 87.9 x 3 Standard 95 x 87 x 3 Cutaway 0.40 - 0.65 micro-chamfer Oversize...
  • Page 144 Repair data Crankshaft .L 31 / .M 31 .L 30 / H .L 30 .L 40 / .M 40 .L 41 / .M 41 Crankpins ∅ mm 60 h 6 64 h 6 -0.019 -0.019 Wear limit 59.88 63.88 Out-of-roundness max. 0.05 0.05 Conicity max...
  • Page 145 Repair data Crankshaft .L 31 / .M 31 .L 30 / H .L 30 .L 40 / .M 40 .L 41 / .M 41 Regrinding during repairs Hardness 50 - 55 50 - 55 Hardening depth Big end bearing internal (installed) +0.083 +0.063 Normal...

  • Page 146: 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 PFR 1 K 80 A 442/11 2 - 4 L 30 17 - 18°...
  • Page 147 Governors L 30. H .L 30 Governor spring Governor weight Speed Application Ident-No. Ident-No. Wire ∅ ∅ mm ≤ 2300 036 012 01 Normal operation > 2300 035 744 01 1500 * 036 014 01 035 729 00 1800 * Generator drive 036 013 01 3000...
  • Page 148 Lubricating oil content and dipstick Oil content Dipstick Engine type Oil sump marking 2-cylinder engines with .L.. C / Z without with .L.. S. M.. without 3-cylinder engines with 10.5 .L.. C / Z without with 11.0 .L.. S. M.. without 4-cylinder engines .L..
  • Page 149 Key to circuit diagrams (DIN 40719) Designation of electrical component Instrument box Instrument panel Automatic start-stop Starter protection module Temperature sensor Speed-pulse transmitter Oil pressure sensor Signal horn Condenser Fuel filter heater Fuse Battery Alternator Flywheel generator Generator telltale light Oil pressure warning light Engine overheat warning light Air filter telltale light (maintenance switch)
  • Page 150 Key to circuit diagrams (DIN 40719) Designation of electrical component Pre-heat plug Heating flange Line resistor for pre-heat system Resistor Line resistor with thermo-time switch Pre-heat start switch (5-position) Master switch Pre-heat/start switch (3-position) Start-stop-switch Switch for speed control Engine temperature switch Oil pressure switch Pressure switch for air-filter Fan monitoring switch...
  • Page 151 HATZ - Wiring identification Terminal Designation Earth (ground) Alternator B+ With alternator: D+ With flywheel generator: terminal L at voltage regulator Starter terminal 50 Oil pressure switch Temperature switch on cylinder head Pre-heat plug I Engine shut-down solenoid Pre-heat II...
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  • Page 162 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 position 3 after starting and to 0 by force; if this is not possi- although pre-heat/starter switch was released. does not return automatically to ble, disconnect the battery at position I.
  • Page 163 Trouble-shooting table for electrical system Trouble-shooting at the battery Malfunction Indication Cause Remedy Terminal voltage drops Poor connections, Eliminate the open Battery not recharged 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...
  • Page 164 Trouble-shooting table for electrical system Trouble-shooting at the battery Malfunction Indication Cause Remedy Inadequate current Sulphuric acid attacs Wash down terminals Corroded terminal 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.
  • Page 165 Trouble-shooting table for electrical system Trouble-shooting at the battery Malfunction Indication Cause Remedy Battery fails pre- Battery was discharged too Check ratings of battery and often and too serverely. generator, if necessary fit a maturely. special „Z“ or „HD“ battery. Battery becomes too warm.
  • Page 166 Trouble-shooting table for electrical system Trouble-shooting at the battery Malfunction Indication Cause Remedy Terminal voltage soon Fault in generator, volta- Repair or renew gene- Rate of charge never adequate. drops to 7 V after ge regulator or wiring rator and voltage regu- recharging (12 V connections.
  • Page 167 Trouble-shooting table for electrical system Trouble-shooting at the starting device Malfunction Indication Cause Remedy Generator telltale light Poor connections (loose Check battery lead and Starter motor does not turn does not come on. or corroded), break in connections, clean cable or short to earth battery poles and termi- when pre-heat/start switch is operated.
  • Page 168 Trouble-shooting table for electrical system Trouble-shooting at the starting device Malfunction Indication Cause Remedy Starter motor turns Lengthy operating Carbon brushes Renew brushes and brush period without mainte- sticking. holder guides. too slowly or can- not turn the engine nance or in tough Carbon brushes worn.
  • Page 169 Trouble-shooting table for electrical system Trouble-shooting at the starting device Malfunction Indication Cause Remedy Noise of rotation. Starter relay defective. Switch of engine manually Starter motor continues to run at once (set speed control lever to „stop“ and discon- after switch was released.
  • Page 170 Trouble-shooting table for electrical system Trouble-shooting at the pre-heat system Malfunction Cause Remedy Short to earth (ground) in a pre- Renew the pre-heat plug. Spiral indiator element (pre-heat monitor) glows heat plug, pre-heat element (fila- brightly almost immedi- ment) is bent and shorting inside ately.
  • Page 171 Trouble-shooting table for electrical system Trouble-shooting at the alternator Malfunction Cause Remedy 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.
  • Page 172 Trouble-shooting table for electrical system Trouble-shooting at the alternator Malfunction Cause Remedy Poor connections, contact resistance Eliminate contact resistance, clean When engine is stop- ped the generator in charge circuit or in the line to the terminals, tighten loose terminals. telltale light burns generator telltale light.
  • Page 173 Trouble-shooting table for electrical system Trouble-shooting at engine monitor and display Malfunction Cause Remedy Leak in oil circuit. Check lines and seals, renew if Sudden pressure drop in lubricating oil circuit. necessary. Oil lost from damaged sump. Renew the oil sump. Defective oil pump.
  • Page 174 Trouble-shooting table for electrical system Trouble-shooting at electromagnetic components Malfunction Cause Remedy Defective electromagnet (e.g. winding Renew electromagnet. Electromagnet does 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.

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