Professional Documents
Culture Documents
2 G 30
2 G 40
Edition: 3.94
Contents
Foreword
3. Basic engine
1. General information 3.0. Cross-reference list
1.1. Technical data 3.1. Injection equipment
1.2. Type plate data 3.1.1. Fuel pressure pipes
1.3. Engine illustrations 3.1.2. Injector
3.1.3. Injection pump
2. Additional equipment
3.2. External components
2.1. Fuel supply system 3.2.1. Cooling air duct
2.1.1. Fuel tank 3.2.2. Oil filler
2.1.2. Fuel filter 3.2.3. Lub.oil line
2.1.3. Fuel feed pump 3.2.4. Crankcase breather
2.1.4. Fuel solenoid 3.2.5. Air-intake manifold
2.2. Airfilter system 3.3. Cylinder head area
2.2.1. Oilbath-airfilter 3.3.1. Cylinder head cover
2.2.2. Dry-type airfilter 3.3.2. Cylinder head
2.2.3. Maintenance indicator, mechanical 3.3.3. Pushrod and pushrod tubes
2.2.4. Maintenance indicator, electrical
3.4. Cylinders and pistons, big-end
2.3. Exhaust system 3.4.1. Cylinder
2.3.1. Exhaust silencer and exhaust pipes 3.4.2. Piston
2.4. Electrical equipment 3.4.2.a Characteristics of pistons and
2.4.1. Starter data of bumping clearance
2.4.2. Alternator 3.4.3. Crankcase cover
2.4.3. Voltage regulator 3.4.4. Oil sump
2.4.4. Glow plug 3.4.5. Conrod
2.4.5. Gearring 3.5. Components, flywheel-side
2.5. Engine-monitoring system 3.5.1. Oil pump
2.5.1. Temperature switch 3.5.2. Flywheel
2.5.2. Oil-pressure switch 3.5.3. Timing cover
2.6. Power take-off, mechanical 3.6. Crankcase and internal
2.6.1. Stubshaft components
2.6.2. Flexible coupling 3.6.1. Crankshaft
2.6.3. Centrifugal clutch 3.6.2. Governor lever
2.6.4. Power take-off flange 3.6.3. Camshaft and governor
2.7. Power take-off, hydraulic 3.6.4. Crankcase
2.7.1. Mounting parts for hydraulic pump 3.6.5. Speed control, internal components
3.6.6. Speed control,
external components
3.6.7. Speed control with integrated
injection timer
3.6.8 Stop lever
3.7. Individual repair
3.7.1. Replacing oil seal rings
(P.t.o.- and flywheel-side)
Contents
We have not included information such as cleaning parts, replacing of "O" Rings, gas-
kets, oil seals etc. since it is assumed, of course, that the mechanic will be aware of the
necessity of carrying out such work.
Use only the tools prescribed or absolutely identical tools when carrying out work of
whatever nature.
Please refer to the instruction book for maintenance work, operating materials and trou-
ble shooting information.
For the rest, please observe the general legal regulations and the regulations of the re-
sponsible professional associations.
Discrepancies may occur between the described features and actual features owing to
special equipment, and it has not been possible to allow for such discrepancies either in
the Workshop Manual or in the spare parts list.
Should you have any difficulties, please contact your nearest HATZ-Service agent.
1. General data
1.1. Technical data
Starter 12 V 1.7 kW
Alternator 12 V 280 W
Battery capacity min. / max. 12 V 66 Ah / 88 Ah
2G . . / 10.92
1.2. Type plate data
1) If required
2) In special cases only, e.g. engines acc. to Federal Authority for Automobilism.
1.3. Engine illustration
2G . . / 10.92
2. Additional equipment
2.1. Fuel supply system
-2- -2-
Preparations: - Preparations: -
Dismantling: Dismantling:
- Disconnect the fuel-supply line 1 with - Disconnect the fuel supply line 1 with
clamping device - 2 - and pull it off the clamping device - 2 - and pull it off the
fuel filter. fuel filter.
- Pull off the fuel return line 2 . - Remove parts # 13 ... 22 , dependent
- Remove parts # 3 ... 12 upon model and requirements.
Inspection / Repair: Inspection / Repair:
- Visual inspection. - Visual inspection.
- Maintenance work as per operating - Maintenance work as per Operating
manual. Manual.
Assembly: Assembly:
- Follow the reverse # procedure when - Follow the reverse # procedure when
assembling. assembling.
- Remove the clamping device - 2 - . Do not overtighten the clamp clip on the
- Refer to the Operating Manual for further filter.
information. - Refer to the Operating Manual for further
information.
2G . . / 10.92
2.1
2.1.1.
2.1.2.
10 11 3 4
12 3 4 7 2
5 6
5
2
1
20 20
21 17 21 17
19 15
21 16
22 13 18 14
22
2.1.3. Fuel feed pump
-2-
Preparations: -
Dismantling:
- Disconnect the fuel supply line 32 with
clamping device - 2 -and pull it off the
fuel feed pump.
- Remove parts # ,.33 ... 40..
Inspection / repair:
This is only required if irregularities which
could be attributable to the feed pump
have been noted when operating the en-
gine (poor suction/pumping action owing
to defect, soiled strainer or leaks)
- Visual inspection for wear and tear, etc.
(Chapt. 5.6)
Assembly:
- Follow the reverse # procedure when
assembling.
Pay attention to adjustment of pump lift.
Chapt. 5.6.
- Conduct a leakage or function check by
pumping with the hand lever.
2G . . / 10.92
2.1
2.1.3.
33 34 35 34
40
39
36
2 32 38
34 34 33
2.1.4. Fuel solenoid
(2-4 ways solenoid)
Function:
With fuel solenoid in operation (with elec-
tric voltage - see Chapt.10 -) the fuel
flows in the sequence 1 2 3 4
through the solenoid. With shut-off volt-
age Stop the direction of flow is 4 3
2 1; the injection pump is therefore
sucked empty.
-2-
Preparations: -
Dismantling:
- Dismantle the fuel supply line with
clamping device - 2 -
Inspection / repair:
- Visual inspection
- Inspection of function
Chapt. 6.2.2.
Assembly:
- Follow the reverse # when assembling.
Note:
If subsequent installation of fuel solenoid
is requested. the injection pump used
must have a small suction chamber, see
sketch B. This allows the engine to come
to a standstill after 10 to 15 seconds.
If the existing injection pump has a big
suction chamber. see sketch A, the
volume must be reduced by using longer
banjo bolts and cap screws.
This advice is also applicable if injection
pump is replaced.
2G . . / 10.92
2.1
2.1.4.
039 514 00
039 557 00
490 214 00
039 557 10
2.2.1. Oilbath-airfilter
Preparations:
Dismantling:
- Remove parts # 1 ... 4.
Inspection / repair:
- Visual inspection, especially for plane
contact surface.
- Maintenance work as per instruction
book.
Assembly:
- Follow the reverse # procedure when
assembling.
Note: Filter with h = 218 is only to be in-
stalled with elevated suction tube; the
lower filter (h = 192) fits on both variants
of suction tube.
- Refer to the instruction book for further
information.
2G . . / 10.92
2.2.
2.2.1.
3/1 3
4
192
3/2 min-1
nmax = 3600
<
= 8212...
< 8213...
= < 9110...
=
2 1 1
3/1 3
3/2
min-1
nmax = 3600
218
2.2.2. Dry-type airfilter 2.2.3. Maintenance indicator,
(not mounted directly mechanical (for dry-type
onto engine!) airfilters only)
Preparations: - Preparations: -
Dismantling: Dismantling:
- Release the hose clips 1. - Unscrew the maintenance indicator 8.
- Remove parts # 2 ... 6.
Inspection / repair:
Inspection / repair: - Visual inspection.
- Visual inspection.
- Maintenance work as per instruction Check the maintenance indicator as
book. follows:
- Generate a vacuum on the maintenance
indicator by sucking forcefully. The visi-
Assembly: ble red area must engage. If necessary,
- Follow the reverse # procedure when renew the maintenance indicator.
assembling. - Before starting up, unlock the service in-
Note: dicator with the reset knob 9.
Check the hose connections at the clean
air side (between engine and filter) for Assembly:
leaks. - Follow the reverse # procedure when
Use only original parts ! assembling.
- Refer to the instruction book for further - Refer to the instruction book for further
information. information
2G . . / 10.92
2.2.
2.2.2
2.2.3.
2.2.4..
1 2
9 10
2 1
3
4
5
6
3 4 5
6
7
1 2
2 1
6
5 4
3
2.2.4. Maintenance indicator, electrical
(applicable for dry-type
airfilters only)
Preparations: -
Dismantling:
- Disconnect the cable connection from
the electrical system.
Note the circuit diagram or wiring
diagram!
Chapt. 10.
- Unscrew the maintenance switch 10.
Inspection / repair:
- Visual inspection.
Assembly:
- Follow the reverse # procedure when
assembling.
- Connect the cable connection to the
electrical system.
Note the circuit diagram or wiring diag-
ram !
Chapt. 10.
- Refer to the instruction book for further
information.
2G . . / 10.92
2.2.
2.2.2
2.2.3.
2.2.4..
1 2
9 10
2 1
3
4
5
6
3 4 5
6
7
1 2
2 1
6
5 4
3
2.3. Exhaust system
Preparations: -
Dismantling:
- Remove the parts dependent upon ver-
sion and as required.
Inspection / repair:
- Visual inspection.
Assembly:
- Follow the reverse procedure when
assembling.
Note:
If a new package of gaskets is installed,
absolute attention must be paid to the two
creased sheet metal radiators A of the
5-fold gasket set (per cylinder) to point to
the exhaust elbow respectively to the
exhaust silencer. See table 2.3.1. If the
exhaust manifold is continued from elbow.
a 4-fold package of gaskets must be
used. The two creased sheet metal radia-
tors B must point with the convex side in
directon of the silencer. See table 2.3.1.
Mount fixing nuts with high-temperature
paste J. Chapt. 9.2.
2G . . / 10.92
2.3.
2.3.1.
AA
AA
BB
BB
Attention:
Magnetic ring 5 and coil 9 are identical
Preparations: - for the 12 V- and 24 V - version; only a
Dismantling: special regulator switch is inserted
- Disconnect the battery. (Chapt. 2.4.3.)
Note the order - / + !
- Disconnect the cable connections from
electrical system.
Note the circuit diagram or wiring Preparations: Chapt. 3.5.2.
diagram !
Chapt. 10. Dismantling:
- Remove parts # .,1 ... 3 - Disconnect the battery.
Note the order - / + !
Inspection / repair: - Disconnect the cable connections from
- Visual inspection the voltage regulator.
If a more extensive repair is necessary, Note the circuit diagram or wiring
contact your nearest specialist work- diagram !
shop or HATZ agent. Chapt. 10.
- Remove parts # 4 ... 10 .
Assembly:
Inspection / repair :
- Follow the reverse # procedure when
- Visual inspection.
assembling.
- Chapt. 4.8.1.
- Connect the cable connections to the
- Chapt. 6.4.1.
electrical system.
Note the circuit diagram or wiring
diagram ! Assembly:
Chapt. 10. - Follow the reverse # procedure when
- Refer to the instruction book for further assembling.
information. - Connect the cable connections to the
electrical system.
Note the circuit diagram or wiring
diagram !
Chapt. 10.
- Refer to the instruction book for further
information.
2G . . / 10.92
2.4.
2.4.1.
2.4.2.
2.4.3.
2.4.4.
2.4.5.
13 13
14 5 4 3
12 2 1 11
6 7 8 10
2.4.3. Voltage regulator 2.4.4. Glow plug
(Alternator)
Attention: the voltage regulator is availa-
ble in different designs: Preparations: -
Difference: Dismantling:
a) Cable connection - Disconnect the cable connection from
b) Switch point of charging indicator lamp the electrical system.
(See Chapt. 6.4.2.) Note the circuit diagram or wiring
c) Voltage 14 V or 28 V diagram !
Chapt. 10.
- Unscrew the glow plug 13
2G . . / 10.92
2.4.
2.4.1.
2.4.2.
2.4.3.
2.4.4.
2.4.5.
13 13
14 5 4 3
12 2 1 11
6 7 8 10
2.4.5. Gearring
Dismantling:
- Detach the gearring 14 from the
flywheel by heating it specifically.
If a new gearring is to be used, the old
gearring can also be drilled open and
chiselled off.
Inspection / repair:
- Visual inspection
Check the tooth profile (engagement)
and, if necessary, file down as required
or use a new gearring.
Assembly:
- Heat the gearring to approx. 80 ... 100 C
and fit it.
Note the engagement position (bevel
pointing towards the starter)!
2G . . / 10.92
2.4.
2.4.1.
2.4.2.
2.4.3.
2.4.4.
2.4.5.
13 13
14 5 4 3
12 2 1 11
6 7 8 10
2.5. Engine monitoring system (Sensors and control components)
Preparations: Chapt. 3.2.1. Preparations: -
Dismantling: Dismantling:
- Disconnect the cable connection from - Disconnect the cable connection from
the electrical system. the electrical system.
Note the circuit diagram or wiring Note the circuit diagram or wiring
diagram ! Chapt. 10. diagram ! Chapt. 10.
- Unscrew the temperature switch 1. - Unscrew the oil pressure switch 2 .
Note:
Inspection / repair: The oil pressure switch can be mounted
- Visual inspection. on various positions of the engine.
- After assembly. short-circuit the tem- This influences the switch point, which is
perature switch to ground (switch key in normally engraved in the housing.
position I). The relevant indicator lamp Inspection / repair:
must light. - Visual inspection (e.g. corrosion-proof.
The switching point is 230 10 C. good conducting surface of electric plug
Since this check is very involved. the connection).
check is normally restricted to a function - Inspection of function with compressed
of the temperature switch using a flame. air (remove switch)
Renew the temperature switch if it is Connect delivery connection of switch to
defective. compressed air supply: connect pres-
sure gauge parallel (0 - 5 bar) .
Assembly: The oil pressure switches with one cable
- Follow the reverse # procedure when connection automatically switch to ground
assembling. if pressure drops (below switch point).
- Connect the cable connection to the The indicator lamp lights. The connection
electrical system! Chapt. 10. to battery of the switch cover must be
- Refer to the instruction book for further minus, Plus- voltage is available at
information. cable connection by oil pressure indicator
lamp or control lamp. Therefore the con-
trol lamp must light if the oil pressure limit
drops.
Assembly:
- Follow the reverse # procedure when
assembling.
- Connect the cable connection to the
electrical system.
Note the circuit diagram or wiring
diagram ! Chapt. 10.
- Refer to instruction book for further infor-
mation.
2G . . / 10.92
2.5.
2.5.1.
2.5.2.
2 2
2
2.6. Power-take-off mechanical
-33- - 24 - 25 -
Preparations: Preparations: -
Dismantling: Dismantling:
- Slacken the Allen screw 1 and unscrew - Remove the retaining screw 3 and
it by two turns. washer 4 .
- Screw in and tighten the forcing - Fit the puller - 24 - 25 - and pretension it
screw - 33 - until noticeable pressure is by screwing in the forcing screw.
exerted on the Allen screw 1. (80 ... 120 Nm)
(80 ... 120 Nm) - Release the coupling piece 5 from the
- Release the stubshaft 2 from the cone cone by vigorously striking the forcing
by striking the forcing screw - 33 - screw with a hammer.
vigorously with a hammer.
Inspection / repair:
Inspection / repair: - Visual inspection
- Visual inspection. Check the outer and inner gearring for
wear and tear.
Assembly:
- Clean the inner and outer cone so that Assembly:
they are free of grease. - Clean the outer and inner cone so that
- Slide on the stubshaft and secure it with they are free of grease.
the Allen screw 1 . - Slide on the coupling piece 5 and
Note the tightening torque ! Chapt. 7.1. tighten it with the retaining screw 3 .
Note the tightening torque ! Chapt. 7.1.
2G . . / 10.92
2.6.
2.6.1.
2.6.2.
2.6.3.
2.6.4.
2 1 33
4 3
5
25 24
7 6 33
10 9 8
24
2.6.3. Centrifugal clutch 2.6.4. Power-take-off flange
-33- -24-
Preparations: - Preparations:
Dismantling: Dismantling:
- Slacken the Allen screw 6 and unscrew - Remove the retaining screw 8 and
it by two turns. washer 9 .
- Screw in and tighten the forcing - Fit the puller - 24 - and pretension it by
screw - 33 - until noticeable pressure is screwing in the forcing screw.
exerted on the Allen screw 6 (80 ... 120 Nm)
(80 ... 120 Nm). - Release the p.t.o. flange 10 from the
- Release the centrifugal clutch 7 from cone by striking the forcing screw
the cone by striking the forcing screw vigorously with a hammer.
- 33 - vigorously with a hammer.
Note:
Inspection / repair: In the case of p.t.o. flanges without
- Visual inspection threaded bores for the puller - 24 - we
If a more extensive repair is necessary. recommend to extract the flange with a
consult your nearest HATZ service two-arm puller.
agent.
Inspection / repair:
Assembly: - Visual inspection.
- Clean the inner and outer cone so that
they are free of grease. Assembly:
- Fit the centrifugal clutch and tighten it - Clean the inner and outer cone so that
with the Allen screw 6 . they are free of grease.
Note the tightening torque ! Chapt. 7.1. - Fit the p.t.o. flange and tighten it with the
retaining screw 8 .
Note the tightening torque ! Chapt. 7.1.
2G . . / 10.92
2.6.
2.6.1.
2.6.2.
2.6.3.
2.6.4.
2 1 33
4 3
5
25 24
7 6 33
10 9 8
24
2.7. Power-take-off, hydraulic
Inspection / repair:
- Visual inspection.
Assembly:
- Follow the reverse # procedure when
assembling.
Pay attention to the note for sealants
Chapt. 9.2.
- Ensure that the seal ring 4 is correctly
seated and. if necessary. bond it in wit
grease.
2G . . / 10.92
2.7.
2.7.1.
3/1
3/2
3
1
2
14 487 6 5
12 21 2 G 30
>
9 = 8211...
11 10 9
13 13
2
1
3/1
3/2
3
1
2
14 48765
2 G 30
12 > 8212...
=
22
> 9110...
=
12
11 10 9 2 G 40
13 15
2
1
3. Basic engine
3.0. Cross-reference list for dismantling
3.1.1. Fuel pressure pipes 3.1.2. Injector
-3- -29 -
2G . . / 10.92
3.1.
3.1.1.
3.1.2.
3.1.3.
3.1.4.
1
2
3 29
5
3 6
7
4 13 8
11 12
9
10
14 25 28
29
15 17 18 20 19
16 16 19 27
30
26
31
22 23 24
21
98.5 0.8 mm
3.1.3. Injection pump
Assembly:
- - Follow the reverse # procedure when
assembling.
Preparations: Chapt. 3.0. The shims 30 between injection pump
and crankcase adjust the start of delivery
Dismantling:
of the injection pump. Therefore refit gas-
- Remove the fuel lines # 14 ... 20.
kets with the previous overall thickness.
Remove the cover and gasket #
The number stamped next to the injection
21"... 24.
pump as from 1988 specifies the thick-
- Remove the cotter pin 25 and pull off
ness of the gaskets, e.g.: stamped num-
the rod 26 from the control rack of the
ber 6 means 0,60 mm gaskets. The two
injection pump.
thin paper gaskets are not measured.
The rod can be pushed upwards from
the governor lever ball head, if neces- Important:
sary. The afore-mentioned is only applicable if
- Position the control rack 27 (bolt) to the either the same injection pump is in-
center of the recess in the crankcase. stalled or a new one resp. repaired pump
- Remove the hexagon nuts 28 - starting is used, which is calibrated exactly acc. to
at the cylinder side. BOSCH-specifications on the test bench.
- Remove the injection pump and gaskets
# 29 ... 30 . Therefore:
Use original-injection pumps from the
Inspection / repair:
HATZ- or BOSCH-Service station only. If
- Visual inspection.
an injection pump was repaired by a
- Chapt. 6.2.
workshop not belonging to the organisa-
- Chapt. 4.1.
tion, this workshop has to guarantee the
Note:
proper repair and the pre-calibration of
- Before mounting, check rod for proper
the injection pump. This only guarantees
dimensions and adjust - if possible - to
the proper function of the engine with
exact length. (fitting dimensions 98.5
- proper output for intended application,
0,8 mm)
- lowest possible values of noise and
ex-haust emission, and
- trouble-free operation.
2G . . / 10.92
3.1.
3.1.1.
3.1.2.
3.1.3.
3.1.4.
1
2
3 29
5
3 6
7
4 13 8
11 12
9
10
14 25 28
29
15 17 18 20 19
16 16 19 27
30
26
31
22 23 24
21
98.5 0.8 mm
3.2.1. Cooling air duct 3.2.3. Lub.oil line
- -
Inspection/ repair:
- Visual inspection Chapt. 7.2.
Assembly:
- Follow the reverse # procedure when as
sembling.
Note the model version and. if neces-
sary. contact your HATZ service agent!
Ensure that the seal ring 18 is correctl\
seated. If necessary, bond it lightly with
grease. Uniformly tighten the securing
nuts
- Make all the connections to the engine.
Chapt. 3.0
2G . . / 10.92
3.2.
3.2.1.
36/2 36 3.2.2.
37/2 37
36/1 37/1 3.2.3.
3.2.4.
3.2.5.
34 33 31/3 34 33
35 31/2 35
31/1 31
28
19 30
17/1 <
= 8211...
26 27 >
17/2 = 8212...
24
19 19
25 25 15
19 23
16
29 19 22
17
19 21 21 19
18
19 20
20
19 19
16
15
4 3 2 5 4 2 1
14/1 14/2 14/3 11 12
3
14 13
5 6
7 8
2
11
12 8 7
10 9
13
3.2.4. Crankcase breather 3.2.5. Air-intake manifold
- -
2G . . / 10.92
3.2.
3.2.1.
36/2 36 3.2.2.
37/2 37
36/1 37/1 3.2.3.
3.2.4.
3.2.5.
34 33 31/3 34 33
35 31/2 35
31/1 31
28
19 30
17/1 <
= 8211...
26 27 >
17/2 = 8212...
24
19 19
25 25 15
19 23
16
29 19 22
17
19 21 21 19
18
19 20
20
19 19
16
15
4 3 2 5 4 2 1
14/1 14/2 14/3 11 12
3
14 13
5 6
7 8
2
11
12 8 7
10 9
13
3.3.1. Cylinder head cover Assembly:
- Measure bumping clearance and pay
- attention to different values (depending
on engine version).
See Chapt. 3.4.2. and 5.1.
Preparations: - - Bond the gasket 10 into the cylinder
Dismantling: head 9 with a little grease.
- Remove parts # 1 ... 4 - Before assembly of cylinder head pay
attention to Chapt. 7.1.
Inspection / repair: The sealing service of cylinder at surface
- Visual inspection to cylinder head gasket was modified.
Check for cracks and damage in the Instead of the former high cylinder head
area of the gasket. nut we now use a nut with a concave
surface collar, as is used for the lower nut.
With the modified gasket surface at
Assembly:
cylinder - upper part - the torque can be
- Follow the reverse # procedure when as-
reduced to 55 Nm.
sembling.
Note the tightening torque !
Ensure that the seal ring 4 is correctly
- Place cylinder head 9 .
seated and, if necessary, bond it with a
Utmost attention must be paid to proper
little grease.
insertion of protection tube!
Tighten the cover uniformly !
Fit the washers 8 and nuts 7 as shown
in the illustration. Note any deviations in
the arrangement.
3.3.2. Cylinder head
Screw down the cylinder head so that it
contacts the cylinder uniformly, but do not
-15- tighten it fully.
Align the cylinder heads parallel by posi-
Preparations: Chapt. 3.0. tioning a straightedge on the intake side
Dismantling: or by temporarily fitting the exhaust mani-
- Remove parts # 5 ... 10. fold without gaskets.
The cylinder head stud 18 normally Tighten the cylinder heads step by step,
needs not to be removed. If this uniformly and crosswise.
becomes necessary (for example if Note the tightening torque
threads are damaged. etc.). place Chapt. 7.1.
graphitized grease onto lower part of During tightening continuously check
thread. whether engine is easy to turn (for exam-
ple at flywheel). If necessary, slightly
reduce the tightening torque at nuts.
If the stud 17 comes loose during dis-
Inspection/ repair: mantling, grease thread slightly with
- Visual inspection. sealing compount C.
- Chapt. 4.2.
2G . . / 10.92
3.3.
3.3.1.
3.3.2.
1 3.3.3.
2
3
4
12 5
6
7 15
17 8
9 10
13
60 Nm 55 Nm
14
15
14
16
- Fit the rocker bracket 11. 3.3.3. Pushrods and pushrod tubes
Ensure that the adjusting screws are
fitted correctly in the push rods and, if -
necessary, unscrew the adjusting screws
accordingly.
- Secure the rocker arm 11 with nuts Preparations: Chapt. 3.0.
12. Dismantling:
Note the tightening torque ! - Remove parts # 13 ... 16.
Chapt. 7.1.
- Adjust tappet clearance Inspection / repair:
Chapt. 5.2. - Visual inspection
- Adjust the eyebolt with shim(s) 5 so Check that the pushrod head and socket
that it is crosswise with respect to the are firmly seated and check them for
engine, and tighten it. wear.
- Make all the connections to the engine
Assembly:
Chapt. 3.0.
- Follow the reverse # procedure when
assembling.
Note:
For engines with series
2 G 30 14...
2 G 40 10...
oil baffles must always be fitted as shown
in the detailed view since, otherwise, this
would involve the risk of inadequate lubri-
cation of the tappets !
For technical improvements at crankcase
these baffles are deleted from series
(2G30 15 ..., 2G40 11 ...).
Chapt. 1.4.
- The pushrods can be interchanged.
Before fitting the relevant cylinder head,
set the pushrods to bottom position by
turning the camshaft.
- Make all the connections to the engine
Chapt. 3.0.
2G . . / 10.92
3.3.
3.3.1.
3.3.2.
1 3.3.3.
2
3
4
12 5
6
7 15
17 8
9 10
13
60 Nm 55 Nm
14
15
14
16
3.4.1. Cylinder 3.4.2. Piston
-5- -
2G . . / 10.92
3.4.
3.4.1.
3.4.2.
5
5 7 9 10
11
4
11 13 12 11
1 2 3
d
C (Bumping
h
Utilization clearance)
A B C D
d h Ident-Nr. c
88.0 012 236 01
1 generelly, expect compressor 40.2 13.6 88.5 012 355 01 0.70 - 0.75
89.0 012 273 01
88.0 013 005 00 (012 236 00)
Compressor 2 G 30 - 151 .. -
2 G 30 2 Compressor 2 G 30 - 172 .. 42.4 14.3 88.5 0.70 - 0.75
89.0 -
88.0 013 005 00 (012 236 00)
3 Compressor 2 G 30 - 157 .. 42.4 14.3 88.5 - 0.60 - 0.65
89.0 -
92.0 012 402 01
2 G 40 4 generelly (incl. Compressor) 43.2 14.4 92.5 012 483 01 0.60 - 0.65
93.0
3.4.3. Crankcase cover 3.4.4. Oil sump
- -
Preparations: Preparations:
- Remove engine mounts # 14" ... 16 - Remove the engine mount # 22"... 25.
Dismantling:
- Remove parts # 17 ... 21. Dismantling:
- Remove parts # 26 ... 32.
Inspection / repair: The suction pipe 33 is sealed in and
- Visual inspection. remains in the crankcase.
It is possible to remove it by heating the
Assembly: suction pipe.
- Follow the reverse # procedure when
assembling. Inspection / repair:
Ensure that the gasket 20" is correctly - Visual inspection
positioned with respect to the contour of If necessary, seal in the suction pipe.
the cover 19 or crankcase ! Pay attention to the note on sealants !
The cover 19 must be fitted with its Chapt. 9.2.
outside recess pointing in the direction
of the power take-off side. Assembly:
- Make all connections to the engine. Fitting the suction pipe
Chapt. 3.0. - After pretreating the suction pipe 33
with activator A, insert it with sealant E
into the intake bore.
The correct installation depth is indi-
cated by tapered lug on the intake pipe.
Pay attention to the note on sealants !
Chapt. 9.2.
- Assemble the other parts in reverse #
order.
Ensure that the gasket 31 is positioned
correctly with respect to the contour of
the oil sump or crankcase !
2G . . / 10.92
3.4.
3.4.3.
3.4.4.
21 33
32
31
20
30
19
18
27
17
26
16 29 28
15 14
25
24
23
22
3.4.5. Conrod
-15-16-
Assembly:
The modification of radius at crankpin of
crankshaft B1 requires increased sized
chamfers at the conrod A1.
The conrod Al with a chamfer of 3 mm
can be utilized for both crankshaft de-
signs. Conrods A1 with a chamfer of
1,25 mm can be used for crankshafts of
design B only. (see also Chapt. 3.6.1.)
- Assemble the conrod on the basis of the
# or broaching cut.
The locking lugs must point towards the
starter side
- Uniformly tighten the conrod bolts 34.
Note the tightening torque !
Chapt. 7.1.
- Make all the connections to the engine
Chapt. 3.0.
2G . . / 10.92
3.4.
3.4.5.
A A1
B B1
~1.25 3 ~3.0 0
2. 4.
R R
35
36
7 15
16
35
34
3.5.1. Oil pump 3.5.2. Flywheel
- -18-19-24-
2G . . / 10.92
3.5.
3.5.1.
3.5.2.
6 5 4 3 21
18 7 8 9 24
10
19
3.5.3. Timing cover Assembly:
Timing cover
- 28 - 29 - - Adjust the axial play of crankshaft and
camshaft.
The axial play is set by fitting one or
Preparations: Chapt. 3.0. more gaskets 19 and is 0,10 - 0,30 mm
Dismantling: for crankshaft and camshaft.
Lub.oil line All measurements must show that
Note the model version ! crankshaft and camshaft sit close in
- Remove the lub.oil line # 11 ... 15. axial direction of the p.t.o. side.
2G . . / 10.92
3.5.
3.5.3.
28
18/1
11 13
11/1
14 18
11/2
12 15
16 29
17 19
22
23
24
25
20
21
26
27
Measured distance Assembly:
Number of Intermediate gear for hydraulic pump
Protrution of
gaskets 19 - Follow the reverse # procedure when
gearwheels
assembling.
0,00 . . . 0,10 1 - Insert the shim(s) 25" in the crankcase.
0,11 . . . 0,30 2 Note the fitting dimension !
Chapt. 7.2.
- Apply sealant to both sides of gasket - Insert the gearwheel 24" and knock in
19" and fit it onto the timing cover. the shaft 23.
Pay attention to the note on sealants ! The extraction thread must point in the
Chapt. 9.2. direction of the timing cover !
- Fit timing cover # 18" ... 16. - Insert the 0-ring 22 into the timing
Ensure that the oil seal ring 18/1 is cover 18 and, if necessary, bond it in
used correctly (twist in clockwise with a little grease.
direction) !
- Position the oil seal ring with impact
sleeve - 28 - .
Dismantling:
Intermediate gear for hydraulic pump
Model version 8211...
- Remove parts # 20 ... 21.
Inspection / repair:
- Visual inspection. - Chapt. 72.
2G . . / 10.92
3.5.
3.5.3.
28
18/1
11 13
11/1
14 18
11/2
12 15
16 29
17 19
22
23
24
25
20
21
26
27
3.6.1. Crankshaft - Position the crankcase top half assem-
Note: bly, preassembled, with bearing side
Upon introduction of the 2 G 40 the pointing upwards,Chapt. 4.7.3.
crankshaft and big end have been modi- - Set the markings on the gearwheel
fied (see also Chapt. 3.4.5.) for the camshaft approximately to the
main bearing bore.
Radius at Chamfer see - Insert the preassembled crankshaft 4
crank pin at big end sketch into the crankcase top half.
Ensure that the markings on the
formerly: 2.3 mm 1.25 mm A-B gearwheel crankshaft/camshaft coincide,
now: 4.0 mm 3.00 mm A1 - B1 and note the position (vertical position)
of the oil seal ring 5 !
- Carefully fit the crankcase bottom half
assembly, preassembled.
Interchangeability: The new big end A1" Ensure that the bearing points, position-
can be used for both crankshafts; use ing pins and oil seal ring are correctly
former big end A with former crankshaft B positioned !
only. Note the sealant instructions.
- Insert the bolts, washers and nuts #
- 27 - 3 ... 1 and tighten the nuts by hand.
- Positioning of oil seal ring by visual
inspection. Adjust, if necessary, with
Preparations: Chapt. 3.0. fixture - 27 -.
Dismantling: - Uniformly tighten the securing bolts.
- Remove the hexagon nut, washers and - Make all the connections to the engine
hexagon screws # 1 ... 3 . Chapt. 3.0.
- Lift off the crankcase top half assembly
from the top. lf necessary, use a screw-
driver etc. in the recesses provided, for
assistance.
- Lift off the crankshaft 4" with oil-seal
ring 5.
Inspection / repair:
- Visual inspection.
- Chapt. 4.5.
Assembly:
Note:
Check easy-running of camshaft by
hand before installing the crankshaft,
Chapt. 3.5.1.
2G . . / 10.92
3.6.
3.6.1.
A A1
B B1
~3.0 0
~1.25
2.3 4.
R R
27
11 7 6
9 10
1
2 b
3
a
8
3.6.2. Governor lever and governor 3.6.3. Camshaft and governor
spring
-
-
Preparations: Chapt. 3.0.
Preparations: Chapt. 3.0.
Dismantling: IMPORTANT !
- Remove the spring cotter 6 . The camshaft must be removed and fitted
- Disengage and remove the governor as described below since, other-wise, the
spring 7 . bearing bores in the crankcase could be
- Pull out the governor lever spindle 8 damaged.
and lift off the governor lever 9 . Dismantling:
- Set the markings on the camshaft
Inspection / repair: gearwheel to the edge of the housing a
- Visual inspection. (approx. 10 o'clock position).
- Chapt. 4.7.1. - Pull out the camshaft (by approx. 40 mm)
until it drops out from the bearing points.
- Turn the camshaft gearwheel clockwise
Assembly: until the markings point to edge b
- Follow the reverse # procedure when (approx. 1 o'clock position).
assembling. - Pull out the camshaft through the front
Ensure that the governor lever moves bearing point.
easily on the spindle ! - Remove the tappets 11.
Reinsert the spring cotter from the top.
- Make all the connections to the engine Inspection / repair:
Chapt. 3.0. - Visual inspection.
- Chapt. 4.6.
Assembly:
- Set the markings on the camshaft
gearwheel to edge b (approx. 1 o'clock
position) and insert it into the bearing
bore.
- As soon as this drops out from the bear-
ing points again, turn the gearwheel
anti-clockwise until the markings
point to edge a (approx. 10 o'clock
position).
- Now fully insert the camshaft through
the rear bearing bore.
Do not use force.
Pay attention to the note
- After fitting the camshaft check its easy
moving.
Chapt. 3.5.1.
- Make all the connections to the engine
Chapt. 3.0.
2G . . / 10.92
3.6.
3.6.2.
3.6.3.
7 6
22
27
11 7 6
9 10
1
2 b
3
a
8
3.6.4. Crankcase Assembly:
Governor lever
- Note the model version !
- Assemble the governor lever in accord-
ance with the instructions
Preparations: Chapt. 3.0. Chapt. 3.6.2.
Dismantling:
- Chapt. 4.7. Model version 8210...
Inspection / repair: Note that the governor lever with bevel
- Visual inspection. and injection quantity limiting screw be-
Assembly: long together
- Assemble as specified in the instructions
Chapt. 4.7. Model version 8211... and 91.10
- Make all the connections to the engine Note that the governor lever with flat and
Chapt. 3.0. extra fuel device belong together !
Dismantling:
Injection quantity limiter
3.6.5. Speed control,
Wherever possible, the injection quantity
internal components limiter should remain unchanged in the
crankcase.
- - If necessary, unscrew the injection
quantity limiter 1.
Dismantling:
Governor lever Inspection:
- Dismantle the governor lever in accord- - Visual inspection
ance with the instructions Check that the extra fuel device moves
Chapt. 3.6.2. easily.
Inspection:
- Visual inspection Repair:
There must be no flattening on the The extra fuel device may be replaced
radius ! only as a complete assembly !
Check the spindle for governor lever and
bore for wear. Assembly:
Repair: Injection quantity limiter
- Replace any parts which are worn
and/or defective. Model version 8210...
The governor lever may be exchanged - Screw the injection quantity limiting
only as a complete assembly screw 1" with hexagon nut into the
crankcase so that it is flush.
Note that the governor lever with bevel
and injection quantity limiting screw
be-long together !
2G . . / 10.92
3.6.
3.6.4.
3.6.5.
3.6.6.
3.6.7.
3.6.8.
<
= 8214...
= 9110...
SCHWARZ ROT
24 BLACK RED
20 22 24/1
23
<
218
224
23/1 = 8215...
23/2 = 9111...
18 19 21 23/3
15 16
14
12 13 8
11
17
9 10
25
26 1
28 27
< 8210...
=
5
8.
~1
<
= 8211...
= 9110... 1
Model version 8211... 3.6.7. Speed control with integrated
- Screw the extra fuel device 1" in until it extra fuel device only for
projects 18.5 mm. with the eccentric 2G30-157 g,
approximately at 11 o'clock position.
2G40-151 d
Note that the governor lever with flat and
extra fuel device belong together Function:
The stop bolt for injection quantity at full
load is grinded to 0,3 mm eccentricity.
Note:
- At high full load speed the governor
In both cases, there is only one basic set-
lever sits close to the unmachined part
ting, which must be corrected by precise
of the bolt (the slot of extra fuel button
setting due to spill or flow measurements.
25" is in vertical position) and injects
Chapt. 5.3.
the quantity required at this speed.
Chapt. 5.4.
- If the speed control lever is turned to
position low" (-) full load speed, the
stop bolt must be turned by 90 and
3.6.6. Speed control,
releases an exactly proportioned higher
external components injection quantity.
- Adjustment:
- Adjustment of performance (delivery lift)
Dismantling: - if necessary - at vertical position of slot
- Remove parts # 9 ... 16 and pull out of extra fuel button.
the acceleration lever 17" towards the - Insert rods 26and secure they can
inside. move within the holes drilled through
without any greater resistance.
Inspection / repair: - Place speed control lever in position
- Visual inspection. high (+) and secure.
- Renew any parts which are worn and/or - Place lever 27 exactly in the position
defective. where the slot at extra fuel button is ver-
tical. Clamp with nut 28 onto speed
control shaft.
Assembly:
- If the speed control lever is placed in
- Follow the reverse t procedure when
position low (-) the button of extra fuel
assembling.
device must turn in horizontal position of
Ensure that the acceleration lever in the
the slot.
crankcase can move easily I
2G . . / 10.92
3.6.
3.6.4.
3.6.5.
3.6.6.
3.6.7.
3.6.8.
<
= 8214...
= 9110...
SCHWARZ ROT
24 BLACK RED
20 22 24/1
23
<
218
224
23/1 = 8215...
23/2 = 9111...
18 19 21 23/3
15 16
14
12 13 8
11
17
9 10
25
26 1
28 27
< 8210...
=
5
8.
~1
<
= 8211...
= 9110... 1
Important Note ! 3.6.8. Stop lever
This device is only mounted and appli-
cable for engine specifications mentioned -
before.
Assembly:
- Follow the reverse # procedure when
assembling.
Ensure that the shaft 24 can move
easily in the cover
2G . . / 10.92
3.6.
3.6.4.
3.6.5.
3.6.6.
3.6.7.
3.6.8.
<
= 8214...
= 9110...
SCHWARZ ROT
24 BLACK RED
20 22 24/1
23
<
218
224
23/1 = 8215...
23/2 = 9111...
18 19 21 23/3
15 16
14
12 13 8
11
17
9 10
25
26 1
28 27
< 8210...
=
5
8.
~1
<
= 8211...
= 9110... 1
3.7.1. Replacing oil seal ring
(power-take-off side)
- 27 - + 2 metal lamellas
(thickness 0,05 mm)
Inspection / repair:
- Visual inspection.
- Check that the oil-seal ring is correctly
seated and check the crankshaft for
scoring and running-in marks.
Assembly:
The oil-seal ring to be fitted on the power
take-off side is identified with a white dot
(twist in counter-clockwise direction of
rotation).
In order to avoid the projecting sealing
cord ends 1 being shorn off when pulling
in the oil-seal ring, the ends must be
pushed back with the aid of two steel
lamellas (thickness 0,05 mm).
- Position the steel lamellas 2 over the
projecting ends of the sealing cords as
far as the base of the oil seal ring bore.
- Fit the oil seal ring 3 and press it in,
using fitting device - 27 -.
- Pull out the steel lamellas 2 .
Note:
Before fitting the new oil seal ring pay
attention to note for sealing material.
2G . . / 10.92
3.7.
3.7.1.
1
2 (0.05mm)
2 3
(0.05mm)
27
4. Components repair work
4.1. Injection equipment
2G . . / 10.92
4.1.
4.1.1.
7
6
1
5
4
3/1
3
34
4.2. Cylinder head
2G . . / 10.92
4.2.
4.2.1.
1
2 7 4
3 6
7 5
8 6
3 2 9 10
10
11
12
16
15/4 16 13 15/3 15/1
15/2
15 9
11 14
15/5 14
12
13
4.3. Cylinder and piston
Assembly:
- It is absolutely necessary to use new
piston rings after honing the cylinder.
2G . . / 10.92
4.3.
4.3.1.
4.3.2.
1 4
2
3
4
6
4.3.2. Piston
-4-
Dismantling: Repair:
- Remove the piston rings # 1" ... 3 from - Before any parts are re-used. they must
the piston with the piston ring pliers - 4 -. be cleaned to remove oil carbon.
Do not interchange the piston rings ! If a new set of piston rings is used, the
cylinder must be rehoned!
Inspection: Chapt. 4.3.1.
- Visual inspection
Check the piston rings for scoring and / Assembly:
or other damage. - Fit the piston rings # 3 ... 1 with
Check the piston for seizing marks and piston ring pliers - 4 -.
or other damage. Note the TOP marking (top) of the
pis-ton rings !
Piston ring gap
- Insert one piston ring in each case in
the relevant cylinder and set to the
position in which it is at TDC of the
piston.
- Align the piston ring with the cleaned
piston crown rectangular to the cylinder
axis.
- Using a feeler gauge, determine the ring
gap (clearance between the two ends of
the piston ring).
If the ring gap is excessive, the piston
rings and/or the cylinder are worn,
(see also Chapt. 4.3.1.).
Note the wear ratings !
Chapt. 7.5.
2G . . / 10.92
4.3.
4.3.1.
4.3.2.
1 4
2
3
4
6
4.4. Conrod
2G . . / 10.92
4.4.
4.4.1.
3
4
2 1
15
16
4.5. Crankshaft
4.5.1. Crankshaft
- 24 - 26 - 28 -
Dismantling: Assembly:
- Pull off the gearwheel 1 with extractor - Fully insert the caps in the 7 mm bore
- 24 - 26 - from the crankshaft 2". and lock by caulking.
When replacing the crankshaft, unscrew Pay attention to the note on sealants !
the threaded bush 4 with the aid of an Chapt. 9.2.
M 10 x 1,5 screw 7, a lock nut 6" and - Heat the gearwheel 1 to a temperature
a spacer bush 19 x 11 x 10 mm 5. of 70 - 80 C and fit as far as the lug
using the impact sleeve - 28 -.
Inspection: The marking on the gearwheel must
- Visual inspection point in the direction of the flywheel
Check the bearing points for seizing cone (outward !).
marks and cracks. etc. - Screw the threaded bush 4 back in,
Note the wear ratings ! Chapt. 7.3. following the reverse procedure to that
for dismantling.
Note: See Chapt. 3.4.5. and 3.6.1. The threaded bush must be flush with
the internal thread of the crankshaft
Repair:
If a general repair is necessary, the caps
3 must be removed as desdribed below
in order to clean the oil ducts:
- Chisel off the caulking and drill out the
cap 3" with a 7 mm drill bit.
Ensure that the bore is neat and not
expanded!
- Clean the oil ducts.
2G . . / 10.92
4.5.
4.5.1.
24
26
28
1 2/1 2/2
2
2/3
5 6 7
4.6. Camshaft and governor
- -
Dismantling: Dismantling:
Camshaft assy. Gearwheel with governor
- Remove the shim(s) 1. - Remove parts # 7 ... 9.
- Press the camshaft 6 out of the gear-
wheel 2. Inspection:
- Dismantle the camshaft # 3 ... 6. - Visual inspection
Inspect the governor weights for wear in
Inspection: the area of the bolt bearing and contour
- Visual inspection surfaces (radius) contacting the
Any run-in marks on the governor sleeve governor sleeve.
4 (governor weight support) or its bear- There must be no flattening on the
ing surface ! governor weights !
Note the wear ratings ! Chapt. 7.4.
Repair:
Repair: - Replace any parts which are worn and /
- Replace any parts which are worn or defective.
and/or defective. The governor weights can be exchanged
only completely, together with the carrier!
Assembly:
Camshaft assy. Assembly:
- Preassemble the camshaft # 6/1"... 3. Gearwheel with governor
Heat the gearwheel 2 to approx. - Follow the reverse # procedure when
180 - 200 C. assembling.
- Slide the camshaft fully into the preas- Note the tightening torque !
sembled gearwheel 2, so that the lock Chapt. 7.1.
ring 6/1 contacts and, at the same Ensure that the governor weights can
time, insert the governor weights into the move easily !
governor sleeve 4.
Do not use force since, otherwise. the
lock ring 3 would be strained ! Ensure
that the governor weights and governor
sleeve move easily !
- The shim(s) 1 are not required until
assembly.
Chapt. 3.5.3.
2G . . / 10.92
4.6.
4.6.1.
4.6.2.
1 2
6/1
6/2 6
3 4 5
8 9
7
4.7. Crankcase
- 1 - 21 - 22 - -
Dismantling: Dismantling:
- Push out the bearing shells 2 and - Push out the bearing shells 6 and
mark the previous installation position. mark the previous installation position.
- Unscrew the lub. oilfilter 3 with strap
wrench - 1 -. Inspection / repair:
If necessary, remove the connection - Visual inspection
piece 4 . Check the bearing shells for scoring and
- Pull out the oil relief valve 5 with pressure marks.
ex-tractor - 21 -. Note the wear ratings !
- Flush through the oil ducts. Chapt. 7.2.
- Flush through the oil ducts.
Inspection / repair:
- Visual inspection Note: see Chapt. 2.7.1.
Check the bearing shells for scoring and
pressure marks. Assembly:
Note the wear ratings ! - Bond in the 0-rings 8 with a little
Chapt. 7.2. grease.
- Always renew the lub. oilfilter when - Insert the sealing strips 7 and, if
repairing the engine. necessary, bond them with a little
- Refer to the Operating Manual for further grease.
information. Apply a little sealant to the relevant ends
Visual inspection of the oil relief valve: in order to provide a reliable seal. P
The ball must neatly contact the seal ay attention to the note on sealants !
seat of the valve body. Chapt. 9.2.
The oil relief valve can be exchanged - Insert the bearing shells 6 into the
only as a complete assembly ! locking lugs of the main bearing bore.
- Check the oil pressure after making all If re-used, fit them at the previous
connections to the engine. installation position.
Chapt. 6.3.1.
Assembly:
- Insert the bearing shells 2 into the
locking lugs of the main bearing bore.
If re-used, insert them at the previous
installation position.
- Drive the oil relief valve 5 fully into the
crankcase using the fitting device - 22 -.
Do not use force since, otherwise, the
valve is damaged!
2G . . / 10.92
4.7.
4.7.1.
4.7.2.
6 7
8
17
7
21
4
5 3
1
4.8. Alternator
2G . . / 10.92
4.8.
4.8.1.
2
1
35
3
x1
4 R 0.3
2
1
35
3
x1
4 R
5. Settings
5.1. Bumping clearance
-7-8-
2G . . / 10.92
5.1.
5.1.1.
8 8
7
1 7
2G . . / 10.92
5.2.
5.2.1.
0.10mm
2 1
5.3. Start of injection setting
The start of delivery as well as injection 2. Instead of the pressure valve holder,
quantity are basically pre-calibrated for all flywheel-side, connect the adapter 30
original injection pumps, delivered by with dial gauge 31 . This guarantees
HATZ and BOSCH. Therefore a new set- the fuel supply either via the fuel tank
ting is not necessary if an injection pump at the engine, by-passing the fuel feed
is replaced. As already described in pump or by a separately placed fuel
Chapters 3.1.3. and 4.1.2., the start of de- tank. The fuel level must be at least 20
livery is determined by the thickness of cm above the injection pump
gasket set 16 used between injection 3. Move the speed control lever towards
pump and crankcase. Therefore use the full load position and fix it.
same thickness of gasket set, 4. After removal of the side cover below
the injection pump secure control rod
- which was used at the engine before. or between governor lever and rack with a
- is applicable by the number stamped thin rubber band 3 between rack of
next to the injection pump in the crank- injection pump and screw 5 ; at this
case (see Chapt. 4.1.2.). position the control rod comes to a first
perceptible stop from its left to right
For exceptional cases, for example on en- movement. In this position only the con-
gines which do not have this number trol rod is in its exact full load quantity
stamped on, or if for other reason the fac- at which the start of delivery is to be
tory-determined set of gasket is nomore determined.
available, or if the crankcase and / or
camshaft have been replaced: The setting procedure is done by relea-
1. Instead of the pressure pipe use a sing the fuel supply to the injection pump;
short and downwards bent overflow for this purpose turn flywheel in sense of
pipe and connect a pressure pump with rotation until fuel emerges at overflow
p < 30 bar at fuel supply line of injec- pipe. Now keep on turning same direction
tion pump. This device is not generally until fuel drops out slowly (approx. 5 - 6
available and we therefore describe drops per sec.).
hereafter a method which allows free
fuel supply (for example from mounted
tank or a test tank).
The actual adjustment procedure is
applicable for both methods.
2G . . / 10.92
5.3.
5.3.1.
15 31
30
8
9
10
11
7 6 12 16
13 0.10mm
14 0.20mm
15 0.30mm
1
2 3
4
4/1
5
Removal of gaskets:
The start of delivery is earlier. (higher de-
gree number)
2G . . / 10.92
5.3.
5.3.1.
15 31
30
8
9
10
11
7 6 12 16
13 0.10mm
14 0.20mm
15 0.30mm
1
2 3
4
4/1
5
2G . . / 10.92
5.4.
5.4.1.
15 31
30
8
9
10
11
7 6 12
13
14
15
4/1
16 3
17
+ -- +
Correction
If fuel emerges even before the effective
delivery lift setting, the injected fuel quan-
tity is too low.
If no fuel emerges at the effective delivery
lift setting. the injected fuel quantity is too
high.
- Dependent upon version, adjust the
quantity-limiting screw 16 or eccentric
17 in direction + or -, tighten it and lock
it with locking paint.
Assembly:
- Shut off the fuel supply.
- Remove the dial gauge - 31 - and spill
device - 30 - .
- Mount parts # 15" ... 8 and tighten the
pipe connection 8" .
Note the tightening torque !
Chapt. 7.1.
- Tighten the clamping piece 7
- Remove the rubber band 3 and fit the
cotter pin 4/1 .
- Make all connections to the engine
Chapt. 3.1.3.
2G . . / 10.92
5.4.
5.4.1.
15 31
30
8
9
10
11
7 6 12
13
14
15
4/1
16 3
17
+ -- +
5.5. Engine speed
2G . . / 10.92
5.5.
5.5.1.
32
5 3 4
2 5
5.6. Fuel feed pump
2G . . / 10.92
5.6.
5.6.1.
"
"c" "b
8
1
2 "a"
1 2
0
0 2 : Gesamthub (100%)
0 1 : Leerhub (50 - 80%)
1 2 : Resthub (20 - 50%)
6.Function tests
6.1. Injection valve
-23-
Preparations:
Chapt. 3.1.2.
Function test:
Preparation
- Connect the pressure pipe with testing
device - 23 - to the pipe connection of
the injection pump.
- Remove the corresponding blank plug
and connect the injection valve.
- Set the speed control lever to Start po-
sition.
- Do not pull the extra fuel button.
Test
- Start the engine with starter.
IMPROTANT !
Keep your hands away from the nozzle
jet.
The jet of a spraying nozzle can cause
blood poisoning.
2G . . / 10.92
6.1.
6.1.1.
23
6.2. Injection pump
-23-
Preparation:
Chapt. 3.1.1.
Function test:
Preparation
- Loosen pressure pipes at injection pump
and connect instead the testing device
23a to the appertaining pressure pipe.
- Set the speed control lever into Start
position.
Do not pull extra fuel button !
Test
- Start the engine with starter.
2G . . / 10.92
6.2.
6.2.1.
400 bar
23a
6.2.2. 4-way-fuel solenoid
Preparations:
- Pull off all hose connections from fuel
solenoid.
Test:
- By turning the starter key in position 1
the valve solenoid gets current. The re-
sult is the flow direction as shown in
sketch A (can be tested by blowing
through air).
- Return starter key to position 0 . The
valve solenoid is cut off from current;
one can hear the klick. Now the flow di-
rection as shown on sketch B must be
the result.
Repair:
- If mulfunction occurs, either replace the
complete valve or replace the electric
component separately.
Assembly:
Fix all hose connections.
2G . . / 10.92
6.2.
6.2.2.
Operation
4 3
1 2
1-2-3-4
STOP
4 3
1 2
4-2-3-1
6.3. Lub.oil pressure
2G . . / 10.92
6.3.
6.3.1.
20
6.4. Alternator-Voltage regulator
- 35 - 36 -
Preparations:
- Chapt. 2.4.2.
- Chapt. 2.4.3.
Versions:
There are two versions of this alternator,
and they differ in respect of the design of
the voltage regulator:
- Previous version with plug connector on
the voltage regulator housing.
- Current version with potted cable con-
nections and non-confusible plug con-
nectors.
All work related to the current regulator
version, in respect of fault finding and
function testing, is printed in bold in the
text below.
Fault finding and fault rectification
Note:
Before conducting any more extensive
checks and inspections, ensure that all
cable connections are firmly seated and
have good contact (no corrosion) and that
there is a reliable ground connection
between the voltage regulator, engine
housing and the battery.
2G . . / 10.92
Type of fault Possible cause Test / remedy
Inadequate charging Voltage regulator and / or coil Measure the no-load circuit volt-
current. section defective age: Dependent upon the
result, replace the voltage regu-
lator and / or coil section.
*) Current version of the voltage regulator with potted cable connections and
non-confusible plug connectors
Function tests
Measuring the charging current
- A voltage of at least 6 V must be meas-
urable at terminal 0 or black cable*,
using the multimeter - 35 - since the
alternator cannot issue charging current
otherwise.
If the voltage is lower than this, check
the cable connections for damage or
charge the battery.
2G . . / 10.92
6.4.
6.4.1.
I (A)
24
20
16
12
129 b
182 124
58 50a 15 19 17 black
P0123 white
red
yellow
P,0,1
30
c
G
a 126
V A (mV)
Measuring the alternator no-load circuit Testing the impulse transmitter section in
the voltage regulator
This measurement permits the alternator
section to be tested without voltage regu- The impulse transmitter section of the
lator and battery. voltage regulator represents the ground
- In order to conduct the measurement, connection of the charging indicator lamp
switch off the engine and disconnect the via terminal L or the white cable* when
connection (plug connection) between the engine is off. As soon as charging cur-
the alternator and voltage regulator (2 rent is supplied, this ground connection is
yellow cables), and connect to the multi- interrupted.
meter - 35 -. - As a check, disconnect the tab connec-
- Start the engine and compare the volt- tor from terminal L or white cable* and
age reading of the multimeter with the connect a test lamp (max. 3 W) between
required value at the corresponding en- terminal L or white cable* and terminal
gine speed. B+ or red cable* (but the black cable
must be reconnected); this lamp must
If the required values are reached, the al- light when the engine is not operating. It
ternator is certainly operating correctly. must extinguish when the engine is run-
Inadequate charging current can thus be ning (upwards of a speed of approxi-
caused only by other components (volt- mately 850 r.p.m.).
age regulator, battery) or faults in the wir- If the lamp does not extinguish, the im-
ing. pulse transmitter section is defective and
If required values are not reached, the al- the voltage regulator must be replaced.
ternator section is defective and must be Note:
replaced. The terminal L or white cable* may be
loaded only with max. 0,5 A.
When conducting tests, connect terminal
L or white cable* to B+ or red cable*
only with a test lamp.
2G . . / 10.92
6.4.
6.4.1.
30
26
22
yellow
yellow
18
G 14
126 10
1000 1500 2000 2500 3000
-1
Voltage measurement n (min )
(without battery and voltage regulator)
between the two yellow cables
(alternating current)
129 b 124
182
58 50a 15 19 17 black
P0123 white
red
yellow
P,0,1
30
c
G
a 126
2 G 30 - 157 [ f
2 G 30 / 2 G 40 2 G 40 - 151 [ c 2 G 30 - 151 [ c
2 G 30 - 172
34 36 28
34 36 26 34 36 92 34 36 31
34 36 26 - 8904
a a
b b
B+ C
Condition: U = 13.2 Volt
7. Tables - wear ratings
Tightening torques for threaded connections
Nm 9.81(10) = kpm
Nm 1.3558 = lb ft
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
2G . . / 10.92
Tightening torques in Nm
Engine type 2 G . .
1 2 3 4 5
11
12 13
6 7 8 9 10
14 15 16/17 18 19 20
23
21 22 14
23a
25 26 27 28
9.1. Special tools and workshop equipments
Engine type 2 G . .
Explanation of classification
Example: 03. 1. 2
Supplier: 1... Supplied by HATZ only
2... Equivalent tool in trade
29 30 31 32
40 41 33
34 35
36
37
39
38
9.2. Sealing and bonding agents
Sealing and bonding agents are available from HATZ for use in maintenance and/or re-
pair works.
All items listed below may be ordered as individual spare parts.
Refer to appropriate spare parts list for ordering.
Note:
The following wiring diagrams refer to
electric equipment which has been sup-
plied completely by HATZ.
In many cases the machine manufacturer
installs the electric equipment.
In this case make use of the wiring dia-
gram of the complete machine.
2G . . / 10.92
10.
Electric equipment with optical malfunction indicator 10.1.
Instruments box
129
151a
86 30 30 85
58
P0123
50a 15 19 17 h
169
85 87a87 8787a 86
P,0,1
30 151c
159
182
151b
85 30
87 123
86 87a 159 159
129 129
white black
30 50 7
124 L G
C red M P
B+
G 121 158 161 162 172
G 126 127
yellow
Engine
Battery
121 Glow plug 158 Fuel shutt off solenoid Wiring to 172 by customer 10
123 Glow controller 159 Diode continuous duty solenoid
124 Governor-rectifier 161 Temperature switch Current consupmtion: 3A at 1
126 Alternator 162 Oil pressure switch Solenoid idle: low speed.
127 Starter 169 Operating hour counter
129 Charging indicator lamp 172 Solenoid for speed
151 Timing relay control
182 Glow starting switch
10.2 Wiring diagram for the electric
equipment with automatic
shut-off device
2G . . / 10.92
10.
Electric equipment with automatic shut-off device 10.2.
Instruments box
129 159
151a 159
86 30 173
58 50a 15 19 17
P0123
85 87a87
P,0,1 177
30
159 87 31
182
151b 15 50 SE
85 30
2)
87 123
86 87a 159 159
1)
white black 159
30 50
124 L G 2)
3
C red M 121 0
7
P S
B+
G 161 162 176
G 126 127 157
yellow 158
Battery