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Repair Manual

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

4. Components-Repair work 6. Function tests


4.1. Injection equipment 6.1. Injector
4.1.1. Injector 6.1.1. Pressure and function test
4.1.2. Injection pump 6.2. Injection pump
4.2. Cylinder head 6.2.1. Pressure and function test
4.2.1. Cylinder head 6.2.2. 4-way-fuel solenoid
4.3. Cylinders and pistons 6.3. Lub.oil pressure
4.3.1. Cylinder 6.3.1. Pressure and function test
4.3.2. Piston 6.4. Alternator and voltage regulator
4.4. Conrod 6.4.1. Function tests and test values
4.4.1. Conrod 6.4.2. Survey of voltage regulator
4.5. Crankshaft
4.5.1. Crankshaft 7. Wear + tear / adjustment data
7.1. Tightening torques
4.6. Camshaft and governor 7.2. Crankcase
4.6.1. Camshaft 7.3. Crankshaft
4.6.2. Governor 7.4. Camshaft
4.7. Crankcase 7.5. Piston/Conrod
4.7.1. Crankcase - bottom half 7.6. Cylinder
4.7.2. Crankcase - top half 7.7. Cylinder head
4.8. Alternator 7.8. Oil pump
4.8.1. Alternator
DUCATI 14 V/18 A 8. Governor - Injection system
8.1. Injection equipment
5. Test and adjustment work 8.2. Governor
5.1. Bumping clearance 8.3. Start of injection
5.1.1 Measuring bumping clearance
9. Special tools / sealants and
5.2. Tappet clearance bonding agents
5.2.1. Setting tappet clearance 9.1. Special tools and test equipment
5.3. Start-of-injection setting 9.2. Sealants and bonding agents
5.3.1. Setting start of delivery
5.4. Injected-fuel quantity setting 10. Wiring diagrams
5.4.1. Adjustment of delivery lift
5.5. Engine speed
5.5.1. Engine speed setting
5.6. Fuel feed pump
5.6.1. Fuel feed pump
Foreword

This Workshop Manual covers the latest technical developments according to


month/year indicated on each page. It has been written in such a way, that it contains all
dismantling and assembly instructions in accordance with the table of contents, includ-
ing all required data etc., so as to permit a trained mechanic to carry out correct and
professional repairs.

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.

It has been assumed that a standard set of workshop tools is available.

Please refer to the instruction book for maintenance work, operating materials and trou-
ble shooting information.

Use only GENUINE HATZ PARTS for repairs!


Only these parts guarantee perfect dimensional accuracy and quality.

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

Type 2G30 2G40


Mode of operation 4-stroke
Combustion method Direct-injection
Number of cylinders 2
Bore / stroke mm 88 / 75 92 / 75
Cubic capacity cm3 912 997
Compression ratio 18 : 1
or 20 : 1
depending on piston variant
Ignition sequ. Cyl. 1 = flywheel side 1-2

Sense of rotation pto-side left

Cooling air required at 3000 rpm m3/min. 10.5


Combustion air required at 3000 rpm m3/min. 1.30 1.42

Net weight approx. kg 85 depending on model

Oil capacity approx. ltr 2.5 without oil sump


incl. filter replacement 3.0 with oil sump
Oil consumption max. 1 % of fuel consumption
(with run-in engine) at full load

Injection pressure (static) bar 250+8

Tappet clearance (20 10 C)


inlet / outlet mm 0.10

Starter 12 V 1.7 kW
Alternator 12 V 280 W
Battery capacity min. / max. 12 V 66 Ah / 88 Ah

Max. perm. inclination in Exhaust side Flywheel side


low high low high
without oil sump 30 17 25 25
with oil sump 30 17 30 25

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

1 Fuel line 18 Lubricating oil line


(Feed pump - fuel injection pump) 19 Exhaust manifold
2 Air deflector 20 Fuel injection pump
3 Oil dipstick 21 Stop lever
4 Fuel return line 22 Speed control lever
5 Injector 23 Fuel feed pump
6 Lifting eye-bolt 24 Lub.-oil filter
7 Starter motor 25 Extra fuel device *
8 Air guide 26 Oil drain plug
9 Air intake manifold 27 Guard
10 Type plate 28 Air guide housing
11 Glow plug * 29 Separable connector
12 Oilbath-airfilter * 30 Voltage regulator
13 Oil-pressure switch 31 Engine mount
14 Rain protection cap * 32 Crankshaft - Power-take-off
15 Oil filler cap 33 Fuel line (Fuel filter - feed pump)
16 Fuel pressure pipe 34 Fuel filter
17 Cylinder head cover

* not existing in every engine model

2G . . / 10.92
2. Additional equipment
2.1. Fuel supply system

2.1.1. Fuel tank 2.1.2. Fuel filter

-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

PFR 2K 60A 493


PFR 2K 60A 511

490 214 00

039 557 10

PFR 2K 60A 493


PFR 2K 60A 515
2.2. Airfilter system

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.

Check the maintenance switch as follows:


- Connect the maintenance switch to the
electrical system. The threaded connec-
tor must be grounded (battery minus).
- Turn the switch key to position I.
- Generate a vacuum on the maintenance
switch by sucking forcefully. The indica-
tor lamp on the dashboard console must
light.
- If there is no reaction, check the cable
connections and, if necessary, check the
bulb and/or renew the maintenance
switch.

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

2.3.1. Exhaust silencer and


exhaust pipes

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

Exhaust Cylinder head

AA

BB
BB

Exhaust Exhaust manifold


2.4. Electrical equipment

2.4.1. Starter 2.4.2. Alternator

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

Preparations: - Inspection / repair:


Dismantling: - Visual inspection; watch out for proper
- Disconnect the battery. seat of glow wire at insert !
Note the order - / + ! - After assembly, check that the glow plug
- Disconnect the cable connections (plug is functioning correctly with the air filter
connections) from the voltage regulator. removed. (Preheating with switch key in
Note the circuit diagram or wiring position II).
diagram ! Fit a new glow plug if it is defective !
Chapt. 10.
- Remove parts # 11 ... 12 . Assembly:
- Follow the reverse # procedure when
Inspection / repair: assembling.
- Visual inspection; - Connect the cable connection to the
- Dynamic function inspection, electrical system.
Chapt. 6.4.1. 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
2.4.5. Gearring

Preparations: Chapt. 3.5.2.

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)

2.5.1. Temperature switch 2.5.2. Oil pressure switch


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

2.6.1. Stubshaft 2.6.2. Flexible coupling

-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

2.7.1. Mounting parts for hydraulic Note:


pump - Due to technical improvements a modi-
fied case is used since end of February
1987 which is sealed by a plain com-
pression ring towards the crankcase.
Preparations: No adjustment of tooth backlash is
Remove any additional equipment necessary.
(air filter, exhaust silencer etc.) which are - During the initial production stage until
in your way. approx. mid of February 1987 paper
Disconnect the hydraulic system from the gaskets were used instead of the seal
engine (hydraulic pump). ring 4 . In this case the tooth backlash
must be adjusted with paper gaskets.
Dismantling: - After tightening the case a tooth back-
- Remove parts 1 ... 4 complete (with lash of approx. 0,15 mm must be evident
hydraulic pump). (comparable with slightly increased tap-
The alignment pins (locking) must pet clearance).
re-main in the crankcase or must be - Alternatively a new case with plain com-
retrofitted in the case of subsequent pression rings may be used.
attachment of an hydraulic pump. - If an hydraulic pump drive must be sub-
- Remove parts 5 ... 8 . sequently installed to older engines, pay
- Unscrew bolts 9 . attention to the serial production code of
- Unscrew the hydraulic pump and pull it the engine (Chapt. 1.4) because the
out of the housing 3 complete with gearwheel for hydraulic pumps is avail-
flange 12. able in 2 different sizes.
- The gearwheel 13 can be removed - In old crankcases the installation of the
from the housing 3 from below. broader gearwheel is not possible be-
- Remove the gasket 14. cause of the less width of the crankcase
- Remove parts # 10 ... 12 from the opening.
hydraulic pump.

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 -

Preparations: Chapt. 3.0. Preparations: Chapt. 3.0.


Dismantling: Dismantling:
- Unscrew the fuel pressure pipes, compl. - Disconnect the fuel lines 4 .
# 1 ... 3, and, if necessary, separate - Remove parts # 5 ... 8 .
them by undoing the pipe clip 3. - Loosen the injector 9 by turning or pull-
Inspection / repair: ing until it can be removed. If necessary,
- Visual inspection use an impact puller - 29 -
Check for fractures and chafing, and - Pull out the injector and remove the seal
check the condition of the sealing cones. ring 10 either from the injector or from
the cylinder head.
Note:
- If necessary, remove parts # 11 ... 13
Two designs of pressure pipes are avail-
able which differ in their inner diameter.
For further details refer to Chapt. 8.1. Inspection / repairs:
- Visual inspection.
Assembly:
- Chapt. 6.1. - Chapt. 4.1.
- Follow the reverse # procedure when
as-sembling.
Fit and tighten the pressure pipes so Assembly:
that they are not strained. - Carefully clean the bore in the cylinder
Note the tightening torque ! head.
Chapt. 7.1. - Always fit a new seal ring 10 .
- Make all the connections to the engine The soft, graphite-coated sealing surface
Chapt. 3.0. must point upwards towards the injector
- Follow the reverse # procedure when
as-sembling.
- Tighten the hexagon nut 5 .
Note the tightening torque !
Chapt. 7.1.
- Make all the connections to the engine
Chapt. 3.0.

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.

When fitting the cover 23 ensure that the


internal stop lever 31 of the shut-off
lever engages behind the tab of the rod in
the direction of the ball head.
- Complete engine. 3.0.

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

- -

Preparations: Chapt. 3.0. Preparations: Chapt. 3.0.


Dismantling: Dismantling:
- Remove parts # 1" ... 14" Note the model version
- Remove the parts, dependent upon
Inspection/ Repair: version 19" ... 29 .
- Visual inspection.
Inspection / repair:
Assembly: - Visual inspection.
- Follow the reverse # procedure when
assembling. Assembly:
Ensure that all air-ducting components - Follow the reverse # procedure when
are fitted! assembling.
- Make all the connections to the engine. Note the model version and, if neces-
Chapt. 3.0. sary, contact your HATZ service agent!
Fit the lub.oil lines so that they are not
strained
3.2.2. Oil filling - Make all the connections to the engine
Chapt. 3.0.
-

Preparations: Chapt. 3.0.


Dismantling:
Note the model version !
- Remove parts # 15" ... 18.
For notes see Chapt. 2.7.1.

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

- -

Preparations: Chapt. 3.0. Preparations: Chapt. 3.0.


Dismantling: Dismantling:
Note the model version ! Note the model version (flat - 36 - or up-
- Remove parts # 30" ... 31 wards - 37 -)
- Dismantle the breather valve 31" # to - Remove parts # 33 ... 37.
31/1 ... 31/3.
Inspection/ repair:
Inspection/ repair: - Visual inspection.
- Visual inspection.
Check the parts for fractures. cracks Assembly:
and aging of the rubber parts. - Follow the reverse # procedure when
assembling.
Remark: The formerly used soft gasket - 35 - is
Do not keep valve diaphragm 31/2 in sol- replaced by a gasket set with 5 metal
vents. containing mineral oil (Petrol, Tri lamella.
etc.) for a longer period (decomposes!). Note the model version (flat- 36 - or up-
For repair work generally replace valve wards - 37 -)
diaphragm. Uniformly tighten the securing nuts.
- Make all the connections to the engine
Assembly: Chapt. 3.0.
- Follow the reverse # procedure when
assembling.
Note the model version and, if neces-
sary. contact your HATZ service agent!
- 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
3.3.1. 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- -

Preparations: Chapt. 3.0 Preparations: Chapt. 3.0.


Dismantling:
- Slacken screw 1 on the trim plate 4 - Remove the circlips 11.
and remove parts # 1... 5 completely - Push out the piston pin 12" by hand
from the top. and lift off the piston 13 .
- Remove cylinder 6.
The studs 7 remain in the crankcase Inspection / repair:
but may be replaced if necessary with- - Visual inspection (Wear and tear,
out having to dismantle the crankcase measure piston rings for wear
top half. (Chapt. 4.3.2.)
Inspection / repair: Assembly:
- Visual inspection; Check for wear and - Insert one circlip 11 (opening up-
tear acc. to chapt. 4.3.2. wards) in advance into the piston pin
Check and, if necessary, replace the bore.
shim 8 and protection caps 9 ... 10". - Fit the piston 13 and insert the piston
Chapt. 4.3. pin 12.
Ensure that the recess in the piston
crown is correctly positioned in the
Assembly: direction of the starter side !
- Fit or slide on the shim 8" and protec- - Fit the second circlip (opening upwards.
tion caps 9 ... 10". Ensure that the circlips are correctly
- Offset the piston ring gaps by 120 in seated
each case. - Make all the connections to the engine.
- Set the scale of the piston ring clamping Chapt. 3.0.
device - 5 - dependent upon the piston.
- Carefully slide the collar over the piston
rings and clamp the tightener. Note:
- Carefully fit the cylinder ! - Due to low-quality fuels in some coun-
As soon as the cylinder has been slid tries the compression ratio (e) for the
over the piston ring, release the tighte- engine 2 G 30 has been increased from
ning strap and remove the clamping 18,0 to 20,0 by a smaller combustion
de-vice. chamber in the piston.
- Slide on the trim plate and lock it with - Engines for special applications as well
screw 1. as the 2 G 40 still have e = 18.0
- Make all the connections to the engine (pis-tons presently used)
Chapt. 3.0. - For details see pict. 3.4.2a
Note:
- For the cylinder there are two designs of
sealing surface for cylinder head. which
determine the tightening torque of the
cylinder head nuts.
- Refer to note on table 7.1a

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

Piston variants and their bumping clearance data


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-

Preparations: Chapt. 3.0.


Dismantling:
- Unscrew the conrod bolts and remove
the conrod 35" separately from the top
and bottom.
The big end bearing 36 can remain in
the conrod.
- Loosely bolt the conrod together.
Note the #. Do not interchange the
parts !
Inspection / repair:
- Visual inspection.
- Chapt. 4.4.

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.

< < <


= 8215... = 9110... = 8216... = 9111...

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-

Preparations: Chapt. 3.0. Preparations: Chapt. 3.0.


Dismantling: Dismantling:
- Remove parts # 1 ... 6. - Remove parts 7 ... 9 .
- Remove the flywheel 10 with puller
Inspection / repair: - 24 -.
- Visual inspection. If an additional equipment is attached,
- Chapt. 7.8. note the corresponding assembly in-
structions. Chapt. 2.4.
Assembly:
- Follow the reverse # procedure when IMPORTANT !
assembling. Use only the puller - 24 - to remove the
- Fit the outer rotor 6 with chamfer in the flywheel. On no account should it be
direction of the inside of the crankcase loosened by striking the crankshaft end
(as shown in the detailed section) ! since this would entail the risk of damage
- Measure the axial play of the oil pump. to the crankshaft drive.
Axial play: 0,01 - 0,05 mm
max. 0.10 mm Inspection / repair:
- Check that the seal ring 4 is correctly - Visual inspection.
seated and, if necessary, bond it in with
a little grease. Assembly:
- Uniformly tighten the retaining screws - Follow the reverse # procedure when
1. assembling.
Note the tightening torque ! Ensure that the washer 8 is correctly
Chapt. 7.1. positioned with the collar pointing
- Before further assembly steps are taken, to-wards the flywheel
check easy-running of oil pump: - Tighten the hexagon nut 7.
Turn timing gear of camshaft (without Note the tightening torque ! Chapt. 7.1.
connection to crankshaft-timing gear). - Make all the connections to the engine
With high resistance check external rotor Chapt. 3.0.
6 for correct installation position
respectively reduce toruqe of screws 1.
- Make all the connections to the engine
Chapt. 3.0.

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.

Inspection / repair: 1. Measure and adjust timing gear of


- Visual inspection. crankshaft:
- Place ruler axial to timing gear of crank-
shaft; determine offset of crankcase
Assembly:
surface.
Lub.oil line
A possible offset (for example regrinded
- Assembly parts # 15 ... 11.
crankshaft) must be adjusted with
Fit the lub.oil line so that it is not
shims 27` (0,2 or 0,3 mm) to
strained
0 ... +0,10 mm.
- Make all the connections to the engine
Normally the offset is 0,10 - 0,30 mm.
Chapt. 3.0.
2. Adjust the camshaft to the crankshaft
Dismantling: - Fit a ruler only on the crankshaft timing
Timing cover gear, measure the offset of the cam-
Note the model version ! shaft gear and compensate for this off-
Timing cover with connection for lub.oil set completely with shims 26 of appro-
line 8212... priate thickness.
- Remove the timing cover # 16 ... 19"
3. Adjustment of axial play
Inspection / repair: - Now fit a ruler to the crankshaft timing
- Visual inspection. gear and shim 26 of the camshaft.
- Measure the distance between the ends
of the straight edges and the crankcase
sealing surfaces. and determine the
number of gaskets 19 required, on the
basis of the table to follow.
Gasket thickness 0.2 mm.

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.

Intermediate gear for hydraulic pump


Model version 8212 ...
9110 ...
- Remove the 0-ring 22 from the timing
cover 18 .
- Extract the shaft 23 with an impact
puller - 29 - and remove the gearwheel
24.
- Remove the shim(s) 25 from the
crankcase.

Note: see Chapt. 2.7.1.

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.

< < <


= 8215... = 9110... = 8216... = 9111...

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.

Performance adjustment which exactly Dismantling:


conforms to the specification must be - Dismantle cover # 18 ... 24 .
carried out on test benches only. Please Inspection / repair:
ask for the data sheet for tests - Visual inspection.
PV - 131 c for 2 G 30 - 157 ..., - Replace any parts which are worn and/
PV - 136 c for 2 G 40 - 151 ... or defective.
Stop lever 20 without second stop limit
welded onto it must immediately be re-
placed by such 21 !

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)

Preparations: Chapt. 2.6.


Dismantling:
- Push out the leaking oil seal ring.

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

4.1.1. Injection valve IMPORTANT


Keep your hands out of the nozzle jet.
- 34 - The jet of a spraying nozzle can cause
damage to your health.
Dismantling: - Correct the injection pressure (if neces-
- Dismantle the injection valve 1 # sary) by adjusting the spring tension
2 ... 8. with shim(s) 7.
Do not interchange the nozzle body 3 Chapt. 8.1.
and nozzle needle 3/1 !

Inspection: 4.1.2. Injection pump


- Visual inspection The expert-repair of an injection pump
Check the nozzle body/nozzle needle includes the exact calibration of the start
for overheating damage. scoring and of delivery (prestroke adjustment) and of
coked-up spray holes. the injection quantity. This work may only
be carried out by authorized servicing
Sliding test agents who have a pump test bench.
- Immerse the nozzle needle in clean fuel.
The nozzle needle must slide down If this is not possible, use a new or a
under its own weight into the seat. re-placement pump (to be obtained by an
authorized HATZ service workshop).
Repair:
- Renew parts which are worn and % or If an injection pump is installed which is
defective. not pre-calibrated, neither
The nozzle body and nozzle needle are - sufficient performance nor
lapped together and must not be inter- - low noise- and exhaust gas values can
changed be assured.
It may even cause severe damage to the
Assembly: engine.
- Follow the reverse # procedure when
assembling.
- Tighten the nozzle-retaining nut 2.
Chapt. 7.1.
Connect the injection valve to the tester
- 34 - and eject into the open air with at
least one stroke per second. Then check
the spray pattern and injection pressure.

2G . . / 10.92
4.1.
4.1.1.

7
6
1
5
4
3/1
3

34
4.2. Cylinder head

4.2.1. Cylinder head Measurement procedure


- Measure the valves and distance
- 9 - 10 - 11 - 12 - 13 - 14 between surface and valve.
- Measure the valve guides only when
fitted !
Dismantling: If the valve guides 16 are to be re-
Rocker arm bracket placed, also measure the bore in the
- Dismantle rocker arm bracket 1 # cylinder head.
2 ... 8. - Measure the valve springs.
Note the wear ratings ! Chapt. 7.7.
Inspection:
- Visual inspection Repair:
There must be no flattening on the - Push out worn valve guides 16 with
radius of the rocker arm ! press-in mandrel - 9 -.
Check that the oil duct in the rocker arm - Fit new valve guides 16 with press-in
bracket is unobstructed. mandrel - 9 -.
Note the wear ratings ! Chapt. 7.7. Note the fitting dimension ! Chapt. 7.7.
- Finish-ream the valve guides with hand
Repair: reamer - 10 -.
- Renew parts which are worn and / or - Re-cut the valve seats with valve
defective re-seating tool -11 - 12 - 13 -.
. Note the wear ratings ! Chapt. 7.7.
Assembly: - Grind in the valves with valve grinder
Rocker arm bracket - 14 - and grinding paste (grain 180 -
- Follow the reverse # procedure when 250) (not necessary if precision grinder
assembling. is used).
Note the axial play of the rocker arms !
Chapt. 7.7. Assembly:
Cylinder head
Dismantling: - Follow the reverse # procedure when
Cylinder head assembling.
- Dismantle the cylinder head ,.9" # - In order to check the lapped-in valve
10 ... 15. seats, insert the cleaned valves and fill
Do not interchange the valves the inlet and outlet port with a little
diesel fuel. No fuel may seep through at
the valve seats.
Inspection:
- Visual inspection
Check for possible overheating damage,
cracks, loose valve guides resp. valve
seat inserts.
Check that the oil duct is unobstructed.

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

4.3.1. Cylinder Repair:


Operation
-6- 1. The honing brush must be moved axial-
ly in the cylinder during rotation.
Drilling machine approx. 80 - 100 r.p.m.
Honing lubricant consisting of lub.oil and 2. Recommended speed of rotation
kerosine 1:1 approx. 80 - 100 r.p.m.
Do not use a higher speed !
Dismantling: -
3. Perform approximately 20 - 30 strokes
Inspection: per minute dependent upon the speed.
- Visual inspection An approximately 45 cross-hatch finish
Check the cylinder for scoring, seizing is produced with this number of strokes
marks and / or other damage. per minute.

Cylinder wear 4. Hone only until this cross-hatch finish is


- Determine the piston ring gap with a perfectly visible.This corresponds to a
new piston ring (compression ring I, honing time of approx. 20-45 seconds
chrome-plated). per cylinder.
The cylinder is unusable if the ring gap 5. After honing, clean the cylinder with hot
is excessive. water and cold cleaning agent, using
Note the wear ratings ! brush: thereafter oil it.
Chapt. 7.5.
Relatively new cylinders which have only ATTENTION !
slight scoring and/or seizing marks or a Do not hone too long.
glazed surface and which thus have Do not dry-hone.
an excessive oil consumption can be Wherever possible, do not exceed the
remachined with a flexible honing above specified speed of rotation.
brush - 6 -. Wear safety glasses !

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

4.4.1. Conrod b) Measure the small end bush 3 only in


fitted condition.
- 15 - 16 - If the bush is replaced, also measure
the bore of the con rod.
Chapt. 7.5.
Dismantling:
- Remove the conrod bolts 1 and sepa- c) Check the conrod with fitted bush 3
rate the conrod. (without big end bearing) for skew. Pay
Do not interchange the parts (these are attention to the note in a) !
marked with pairing numbers) The conrod must not be re-aligned !
- Remove the big end bearing 2. Note the wear ratings !
Do not interchange the hearing shells Chapt. 7.5.
See Chapt. 3.4.5. and 3.6.1.
Repair:
- Press out the bush 3 of the conrod.
Inspection: Ensure that the conrod is not bent !
- Visual inspection - Press the bush 3 for the conrod
If the big end bearing is damaged and if centrally into the upper conrod eye.
the conrod can apparently be reused, Check that the lubrication passages
always check the conrod for skew. coincide !
Measuring procedure c. - Renew the conrod bolts 1 at least after
they have been loosened and tightened
Measuring procedure# 3-times !
a) Measure the conrod with and without
conrod 2"
Assembly:
Note: - Fit the big end bearing 2 into the
The conrod must be normally bolted. locking lugs of the conrod 4.
Note the tightening torque ! Ensure correct mating of the big end
Chapt. 7.1. bearing with the crankshaft pin !
- Loosely bolt the conrod.
Note # and paired parts

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

4.6.1. Camshaft 4.6.2. 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

4.7.1. Crankcase bottom half 4.7.2. Crankcase top half

- 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

4.8.1. Alternator Ducati 14 V/18 A B. Resistance measurement - short circuit


to ground
-35- - Test for short circuit to ground with a
multimeter - 35 -.
Preparation:
Dismantling: Set to x 100 / scale
- Separate the stator 1 and rotor 2. Terminal = black measurement lead
Terminal = red measurement lead
Inspection: Short the measurement leads and set
- Visual inspection the pointer to full-scale deflection 0
Check the winding section of the stator with potentiometer adjustment knob.
1 and magnet section of the rotor 2
for damage and / or loose magnets. Measuring procedure
- Test cable 3 resp. 4 with respect to
A. Resistance measurement at coil ground !
section and continuity or interturn short There may be no reading (pointer
- Test for continuity with a multimeter -35- deflection) in either case (R = . If the
Preparation: resistance is smaller - close to 0 W -,
Set to x 1 / scale the coil has short circuit to ground). The
Terminal = black measurement lead above checks must be conducted
Terminal = red measurement lead independently of the no-load current
Short the measurement lead and set the check or charging current check and
pointer to full-scale deflection 0 with before installation in the engine !
potentiometer adjustment knob. These checks only allow a first judge-
ment on the condition of the coils.
Measurement procedure A clear judgement of the function is
- Conduct measurement crosswise on given by dynamic tests, during which the
cables 3 - 4. coils have reached the operating
Full continuity must be indicated in both temperature. (Chapt. 6.4.)
cases R, as indicated on sketch.
If the indication is higher or R = , an Repair:
interruption (breakage) of the winding is - Renew parts which are defective.
evident; if the indication is lower If defects are established, parts must not
( 0,3 W), which can be investigated be reused.
only with high-precision measurement
units, the coil has a short circuit.
Assembly:
- Assembly in accordance with the
instruction.
Chapt. 2.4.2.

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

5.1.1. Measuring the bumping


clearance

-7-8-

Preparations: Chapt. 3.3.2. Bumping clearance nominal value


If the piston, cylinder, conrod, crankshaft (dimension c)
and / or crankcase has been replaced, al- This value depends on - engine type and
ways ensure that the correct bumping - design of piston
clearance is observed.
If the bumping clearance is too small, this For details: see Chapt. 3.4.2a
involves the risk of damage to piston, cy- Assembly:
linder head and valves. - Remove the retaining bracket - 7 - .
If the bumping clearance is too large, the - Make all connections to the engine
engine power will drop, as will the start- Chapt. 3.3.2.
ability.
For the setting of the correct bumping
clearance gaskets b of various thick-
nesses (see sketch) are vailable .
Setting:
Preparation
- Clamp the cylinder down slightly with a
gasket 1 of defined thickness with the
retaining bracket - 7 - .
- Place the depth gauge - 8 - and hold it
firmly.
Ensure that you measure on the piston
crown and not in any recesses !
Measurement procedure
- Crank the engine until the piston has
reached and passed top dead center
TDC..
Compare the indicated value c on
depth gauge with nominal value and
place the gasket of required thickness
(instead of the first one used).
For safety reasons repeat measurement
procedure.
Use only one gasket in each case !

2G . . / 10.92
5.1.
5.1.1.

8 8
7

1 7

Cyl. head gasket


b = 0.6 / 0.7
0.8 / 0.9
0.9 / 1.0
1.1 / 1.2 mm
c (Bumping clearance)
5.2. Tappet clearance

5.2.1. Setting tappet clearance

Preparations: Chapt. 3.3.1. Measurement procedure


Setting method - Measure the tappet clearance with a
Set only with engine cold (20 10 C) . feeler gauge.
Cylinder 1 = flyhweel-side - clockwise Note the setting dimension !
rotation. Chapt. 1.1.
Cylinder 2 = power-take-off side - anti-
clockwise rotation. Correction
Note the direction of rotation - If it is necessary to correct the tappet
- Crank in the direction of rotation until the clearance, loosen hexagon nut 1 and
valves of the second cylinder are in adjust the adjusting screw 2 so that,
rocking position. after retightening the hexagon nut 1
- Turn the crankshaft through 180 in the the feeler gauge 3 can be pulled
direction of rotation and check the tap- through with slightly perceptible resist-
pet clearance of the first cylinder. If nec- ance.
essary, re-adjust. Assembly:
- Turn the crankshaft through a further - Make all connections to the engine
180 and check the tappet clearance of Chapt. 3.3.1.
the second cylinder. - Refer to the Operating Manual for further
If necessary, re-adjust. information.

2G . . / 10.92
5.2.
5.2.1.

0.10mm

2 1
5.3. Start of injection setting

5.3.1. Setting the start of delivery

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

8210... 8213... : 260.5


>
= 8214... : 230.5
>= 9110... : 260.5
This point is start of delivery of injection When the delivery begin is correctly ad-
pump which must be compared with the justed and the injection pump is pre-cali-
corresponding required value. brated according to our standard - see
For this purpose different marks are avail- Chapt. 4.1.2. - you may now punch the
able at the flywheel. thickness of the shims into the crankcase
Crank the engine in the direction of rota- (in 1/10 mm) in order to avoid repeating
tion at the flywheel until the first dot mark- the whole procedure if the injection pump
ing or the degree numbers PM are visi- has to be exchanged at a later date.
ble in the inspection opening of the air- Assembly:
ducting housing. - Shut off the fuel supply.
In case of flywheels with degree marking - Remove the dial gauge - 31 - and spill
the moment of effective start of delivery device - 30 - .
value - as shown - must match with the - Mount parts # 15 ... 8 .
dotted marking ,.PM" on the air-ducting - Tighten the pipe connection
housing. If this is not evident at the first Note the tightening torque!
check of start of delivery correction is Chapt. 7.1.
made with gaskets between injection - Tighten the clamping piece 7 ... 6 .
pump and crankcase. The following rule is - Remove the rubber band 3 and fit the
applicable: cotter pin 4/1 .
- Make all connections to the engine
Adding of gaskets: Chapt. 3.1.3.
The start of delivery is delayed. (lower de-
gree number).

Removal of gaskets:
The start of delivery is earlier. (higher de-
gree number)

If an adjusting device 30 with dial gauge


31 is used, the thickness of the shims
necessary to correctly adjust the delivery
begin can be read off the gauge directly.
If an adjustment device is not available,
one has to try different shims to find the
correct adjustment.

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

8210... 8213... : 260.5


>
= 8214... : 230.5
>= 9110... : 260.5
5.4. Injected fuel quantity setting

5.4.1. Adjustment of delivery lift The adjustment procedure is as follows:


Note:
With the delivery lift (see Chapt. 1.3.) the -15-30-31 -
output of the engine is defined and ad-
justed. The following restrictions are ap- Preparation:
plicable: Set the start of injection (delivery begin)
Chapt. 5.3.1.
The output adjustment of the engine is The injected fuel quantity is determined
exactly determined during a test run in by the travel of the pump plunger between
our works or (for example after a general start of delivery and end of delivery =
overhaul) on the test bench of a HATZ delivery lift.
authorized workshop and is leaded there- This dimension is specified on the type
after. Therefore no modification should be plate (NH) in millimeter
made to this original adjustment. This is Chapt. 1.3.
especially applicable if an injection pump The setting method described below pro-
was replaced by a new one or by an vides a method of theoretical output ad-
expertly repaired injection pump (see justment. Determining the output exactly
Chapt. 4.1.2.) . The pre-calibration of the can be carried out only with a test run on
injection pump avoids any deviation of in- a dynamometer !
jection quantity and therefore of the en- Adjustment:
gine output. However, the output adjust- - Determine the start of delivery
ment by a static measurement of the Chapt. 5.3.1.
delivery lift is not sufficiently accurate to - Set the dial gauge - 31 - to 0 at start of
guarantee a determined output of the en- delivery and open the fuel supply.
gine. - Turn the flywheel further in direction of
rotation until the dimension specified on
The adjustment of delivery lift should only the type plate or specified by a HATZ
be carried out (as a makeshift) if by un- service agent is reached.
professional work on the engine the orig- This point is end of delivery.
inally adjusted output is nomore given - Fix the flywheel in this position.
(noticeable if the coloured lead of adjust- - In this position, the fuel must emerge
ment screw 16 ..17 is destroyed, or if drop by drop from the spill pipe of the
the engine device - 30 -
- either lacks power, or (approx. 1 drop every 5 - 6 seconds).
- at continuous operation (except the
start) shows repeated smoke develop-
ment.

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

5.5.1. Engine speed setting - mech.


Setting the low-idle speed:
-32- - On engines with blocked low-idle speed
setting, the speed is set with the stop
Preparation: screw 5 to approx. 900 - 1000 r.p.m.,
- Remove the pipe clamp 1 unless a speed other than this is re-
- Clamp the sensor of the tachometer quired by the equipment manufacturer.
- 32 - to one of the two fuel pressure Note the information on the type plate
pipes ! PV . Chapt. 1.3.
Note the r.p.m. specified on the type - After adjustment, lock the stop screws
plate. Chapt. 1.3. and lock nuts with locking paint or lead-
seal them.
Note:
Instead of the pictured (and as HATZ spe- Assembly:
cial tool available) revolution counter with - Remove the sensor of the tachometer
pressure-pipe sensor you may also use - 32-.
other instruments available on the market. - Mount the pipe clamp 1 .
Setting the high-idle speed:
Engine stop
- Start the engine and let it warm up.
Stop the engine with stop lever 6 .
- Loosen lock nut 2 and unscrew the
stop screw 3 .

Set the engine to the required high-idle


speed and adjust the stop screw 3 so
that the travel of the speed control lever
4 is limited at the speed reached.
Always move the speed control lever 4
from idle position to full-load position and
conduct the corresponding measurement.

2G . . / 10.92
5.5.
5.5.1.

32

5 3 4

2 5
5.6. Fuel feed pump

5.6.1. Fuel feed pump


- It is sufficient to carry out the idle-/resid-
-8- ual stroke test. A new adjustment
becomes necessary if - either no resid-
ual stroke - or too low an idle stroke
Preparations:
(< 50 %) is evident.
Chapt. 3.1.4.
- Make all connections to the engine
Adjustment: Chapt. 3.1.4.
Preparation
- Check that the thrust pin 1 is able to
move easily in the crankcase.
- Crank the engine until the actuating cam
or thrust bolt is in bottom-most position.
Measurement procedure
- Measure dimension b (projecting
length).
- Fit gaskets 2 and 3 of appropriate
thickness until the prescribed dimension
c is reached.
At all events, use one gasket 2, fitted
on the crankcase side !
Assembly:
- Crank the engine until the actuating cam
or thrust pin is at top-most position.
- Mount the fuel feed pump.
Chapt. 3.1.4.
- After assembly (thrust pin at top-most
position) manually operate the fuel feed
pump. There must be residual stroke on
the actuating lever.
Conducting the above check is ex-
tremely important in order to avoid dam-
age in the area of the pump diaphragm
resulting from excess stroke !
If a fuel feed pump is replaced and no
wear and tear is noticed on the thrust
pin 1 ,the exact measurement and ad-
justment of dimension c is not neces-
sary.

2G . . / 10.92
5.6.
5.6.1.

"
"c" "b

8
1

2 "a"

"a" = 34.1 0.1mm


"c" = 1.8 2.1 mm

1 2
0

0 2 : Gesamthub (100%)
0 1 : Leerhub (50 - 80%)
1 2 : Resthub (20 - 50%)
6.Function tests
6.1. Injection valve

6.1.1. Pressure and function tests

-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.

- Check the spray pattern and injection


pressure.
If the spray pattern is poor or if the
opening pressure is not correct. repair
the injection valve.
Repair:
- Chapt. 4.1.1.
Assembly:
- Remove the testing device - 23 -.
- Make all connections to the engine
Chapt. 3.1.2.

2G . . / 10.92
6.1.
6.1.1.

23
6.2. Injection pump

6.2.1. Pressure and function test

-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.

If the jet of nozzle is clean in spite of the


extremely high opening pressure, it
proves that the injection pump is mechan-
ically in a good condition (wear of pump
element and / or pressure valve).
Repair:
- Chapt. 4.1.2.
Assembly:
- Remove the testing device - 23 -.
- Make all connections to the engine
Chapt. 3.1.1.

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

6.3.1. Pressure and function test


Test conditions:
-20- 1. correct viscosity class
2.Oil temperature: 100 20 C
Preparations:
Oil pressure
Chapt. 3.2.3.
Function test: Speed lower
normal
The lub.oil pressure is influenced by the r.p.m. limit
- pumping capacity of the lub.oil pump 900 1,2 ... 2,5 0,4*
(dependent upon the engine speed) 1500 1,8 ... 3,5 1,0
- the viscosity class and temperature of 2300 2,5 ... 4,5 1,8
the oil, 3000 3,5 ... 5,0 2,5
- the wear on the bearing points,
* lower engaging point of oil pressure
- the function of the relief valve.
switch
The measurement must always be con- Test
ducted with the engine warm from oper- - Start the engine and allow it to warm up.
ation ! Measure the lub.oil pressure at various
The values in the table refer to indicated engine speeds.
conditions only, however take inaccuracy Note the minimum oil pressure !
of measuring instruments into consider- Chapt. 1.1.
ation. Extreme deviations below this value indi-
cate heavy wear on the bearing points
Preparation
or in the oil pump.
- Remove the oil pressure switch or screw
plug (dependent upon version) Repair:
Chapt. 2.5.2. - Chapt. 4.7.2.
Chapt. 3.2.3. Assembly:
- Connect the oil pressure gauge with - Remove the oil pressure gauge - 20 -.
flexible connection -20-. - Make all connections to the engine
Chapt. 2.5.2.
Chapt. 3.2.3.

2G . . / 10.92
6.3.
6.3.1.

20
6.4. Alternator-Voltage regulator

6.4.1. Function test

- 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

The charge indicator Lamp defective. Fit a new lamp.


lamp does not light
when the switch key Cable connection between igni-
is in position I and tion switch (terminal 15) and
with the engine terminal "L" or white cable* of
switched off the voltage regulator defective.
Inadequate ground connection Make good, non-corroded con-
between voltage regulator and nections
engine
Impulse transmitter section of Inspect the impulse transmitter
the voltage regulator, terminal section in the voltage regulator.
"L" or white cable* defective Replace the voltage regulator

The charge indicator No charging current:


lamp does not extin- - No voltage at terminal "C" or Check the cable connection
guish when the black cable* when the switch
engine is running key is in position I.
- Defective voltage regulator Measure the no-load circuit volt-
and / or coil section age: dependent upon the result,
replace the voltage regulator
and / or coil section
- Impulse transmitter section of Check the impulse transmitter
the voltage regulator, terminal section in the voltage regulator.
"L" or white cable* defective Replace the voltage regulator.
(this does not affect the charg-
ing current).

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.

Battery is over- Voltage regulator defective Measure the charging current


charged (gassing). (remains at maximum value
even with battery voltage > 14 V).
Replace the voltage regulator.

*) 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.

The charging current flows from the alter-


nator to the voltage regulator (terminal
G or plug connection of the yellow
cables) and from terminal B+ or red
cable* of the voltage regulator to the bat-
tery.
- In order to conduct measurement, dis-
connect the cable or the plug connec-
tion of the red cable* connected to ter-
minal B+ and connect the multimeter
- 35 - (with the multiplier resistor - 36 -**)
inbetween. Turn the key for glow starting
switch to position 1.
- Start the engine, load the battery (switch
on the loads) and compare the reading
of the multimeter - 35 - (DC) with the
curve of the charging current.
- If the multimeter indicates correct charg-
ing current, the fact that the charging
indicator lamp does not extinguish is at-
tributable to a defective impulse trans-
mitter section of the voltage regulator.
- If the multimeter indicates no charging
current or only inadequate charging cur-
rent, either the voltage regulator or the
alternator section is defective.
- Measure the no-load circuit voltage of
the alternator in order to localize the
fault still further.
*) Current version of the voltage regulator with potted cable connections and
non-confusible plug connections.
**) The multiplier restistor becomes necessary if the measuring range of the multimeter
is below 20 A. For the use of the muliplier resistor please note:
Switch mulitmeter to mV (DC). The indicated numerical value for mV corresponds
to the numerical value of the charging current in ampere.

2G . . / 10.92
6.4.
6.4.1.

Charging current curve


for alternator 14V / 18A Ducati

I (A)
24

20

16

12

1000 1500 2000 2500 3000


n (min-1)
Battery voltage max. 13 V

129 b
182 124
58 50a 15 19 17 black
P0123 white
red
yellow
P,0,1
30

c
G
a 126

124 voltage regulator


126 alternator
129 charging indicator lamp
182 ignition switch

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.

*) Current version of the voltage regulator


with potted cable connections and non-
confusible plug connections

2G . . / 10.92
6.4.
6.4.1.

Idling voltage curve


for alternator 14V / 18A Ducati
U (V)
34

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)

Testing the impulse transmitter section


in the voltage regulator

129 b 124
182
58 50a 15 19 17 black
P0123 white
red
yellow
P,0,1
30

c
G
a 126

124 voltage regulator


126 alternator
129 charging indicator lamp
182 ignition switch
6.4.
6.4.2.

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

a) 502 838 00 a) 503 653 00


Ident.-Nr. 502 838 10 503 746 00
b) 502 839 00 b) 503 654 00

n 900 min n 1300 min-1 n 900 min-1


-1
B+
L

B+ C
Condition: U = 13.2 Volt
7. Tables - wear ratings
Tightening torques for threaded connections

General requirements in Nm:

Nm 9.81(10) = kpm
Nm 1.3558 = lb ft

Screw strength rating


Thread
5.8 8.8 10.9 12.9

M 4 1.7 2.8 3.9 4.7

M 5 3.4 5.5 7.8 9.3

M 6 6.0 9.5 13 16

M 8 14 23 33 39

M 10 29 46 65 78

M 12 50 80 110 140

M 14 80 130 180 220

M 16 120 190 270 330

M 18 170 270 380 450

M 20 240 380 530 640

M 22 320 510 720 860

2G . . / 10.92
Tightening torques in Nm

Cap nuts on fuel pressure pipe 25


Hexagon nut - injection valve retention 23
Nozzle retention - injection valve 60
Hexagon nuts - injection pump retention 23
Pipe connection of injection pump 35
Hexagon nuts - rocker bracket retention 23
Hexagon nuts - cylinder head retention 50/60*
Hexagon nut - flywheel retention 200
Hexagon screw for crankcase cover 10
Big end bolts 40
Hexagon screws for oil pump cover 6
Hexagon screws for timing cover retention 10
Hexagon screws for crankcase halves 10
Hexagon nuts - governor weight holder 7
Flat collar nut at crankshaft- pto-side 250
Allen screw M 10 at crankshaft - pto-side 50
8. Governor - injection system
9. Special tools / sealants and
bonding agents
9.1. Special tools and workshop equipments

Engine type 2 G . .

No. Ident-Nr. Code Designation

1 620 307 01 01.1.2 Strap wrench


2 668 383 00 01.1.2 Clamping device for fuel line
3 613 728 00 03.2.2 Flare nut wrench 17 - 19 mm
4 612 090 01 03.1.2 Piston ring pliers
5 626 383 00 03.1.2 Piston ring clamping device 0 70 - 100 mm
6 624 842 00 03.1.2 Hone brush / 120 grit
7 625 742 00 03.1.1 Retaining bracket for cylinder
8 603 114 01 03.1.2 Depth gauge
9 669 348 00 03.1.1 Press-in mandrel for valve guide 0 8 mm
10 612 109 00 03.1.2 Reamer 8 H6 for valve guide
11 612 105 00 03.1.2 Guiding pin 0 8 mm for valve reseating tool
12 612 103 00 03.1.2 Valve reseating tool 0 42.5 mm
13 670 323 00 03.1.2 Handle for valve reseating tool
14 625 859 00 03.1.2 Suction cap valve grinder 0 30 mm
15 612 088 01 03.1.2 Torque wrench 20 ... 200 Nm 1/2"
15 630 430 00 03.1.2 Torque wrench 5 ... 60 Nm 3/8"
16 612 091 00 03.1.2 Allen socket 6 mm 1/2"
17 612 095 00 03.1.2 Allen socket 8 mm 1/2"
18 626 281 00 03.1.2 Adaptor 3/4" - 1/2" for 625 661 00
19 625 661 00 03.1.2 Torque wrench 70 - 400 Nm - 3/4"
20 620 926 01 03.1.1 Oil pressure gauge 0 - 6 bar with flex. line
21 625 689 01 03.1.1 Extractor for oil relief valve
22 626 729 00 03.2.1 Fitting device for oil relief valve
23 604 628 00 03.1.1 Testing device for injection equipment
23a 630 094 00 03.1.2 Test nozzle 400 bar with pressure pipe
24 625 687 01 03.1.1 Extractor for flywheel
25 627 603 00 06.1.1 Extractor for flexible coupling (Bowex)
26 625 748 00 05.1.2 Extractor for gearwheel on crankshaft
27 625 688 00 03.1.1 Fitting device for oil seal ring
28 625 747 00 05.1.1 Impact mandrel for gearwheel on crankshaft
9.1.
9.1.1.

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 . .

No. Ident-Nr. Code Designation

29 626 753 00 03.1.1 Impact hammer with fittings


30 665 030 01 05.1.1 Spill device for injection pump
31 612 087 00 05.1.2 Dial gauge - 1 / 100 mm
32 624 838 01 03.1.2 Rev. counter for fuel pressure line
33 503 298 00 03.1.2 Forcing screw M 12 x 1,5 x 25
34 625 010 00 03.1.2 Tester for injection nozzle
35 625 383 01 03.1.2 Electric multimeter
36 626 416 00 03.1.2 Multiplier resistor
37 625 682 01 05.2.1 Revolvable fixing; basic part
37 631 125 00 05.2.1 Revolvable fixing; adaptor engine-side
38 625 751 00 05.2.1 Console for "37"
39 624 863 02 05.2.2 Hydraulic lift trolley for 37 + 38

Explanation of classification

Example: 03. 1. 2
Supplier: 1... Supplied by HATZ only
2... Equivalent tool in trade

Necessity: 1... Absolutely necessary


2... Suitable

Kind of repair: 01. . . Maintenance


02. . . Emergency repair
03. . . Repair in upper and external area
05. . . Repair in area of driving gear
mechanism
5Q. . . Overhaul of engines
(including all necessary tests)
06. . . Repair of components
9.1.
9.1.2.

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.

Application of sealing and bonding agents:


The letter coding in the drawings indicates which agents should be applied when fitting
the part refered to.
See the following list for decoding the material; this list is the same as already being
used with all other service literature including spare parts list.

A = 502 230 01 Loctite Activator 500 ml


B = 502 231 00 Loctite 573 50 ml
C = 502 232 00 Loctite 601 50 ml
D = 502 233 00 Loctite 221 50 ml
E = 502 234 00 Loctite 648 10 ml
F = 502 238 00 Technicoll 8058 750 g
+ 502 239 00 Technicoll 8367 750 g
G = 502 565 01 Loctite IS 407 20 g
H = 502 825 01 Silicon sealer 30 ml
J = 502 830 02 Anti-Seize compound 1000 g
K = 503 426 00 High-temp. lub.-grease 100 g
L = 502 566 00 Silicon sealer 100 g
M = 504 851 00 polishing paste K 240r 80 ml
10. Wiring diagrams
10. Wiring diagrams

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.

10.1. Wiring diagram for electric


equipment with optical mal-
function indicator

This equipment indicates malfunctions


optically (indicator lamp 129). If a solenoid
or the fuel shut-off solenoid 158 is mount-
ed, it is used to shut off the engine with
the "ignition key".

The relays 151 a and 151 b protect the


engine against re-start while engine is
running.
The corresponding description of function
can be obtained from your HATZ service
agent.

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

With this equipment malfunctions are indi-


cated by the sensors "161" and "162" to
the engine protection relay "177" which
shuts off the engine via the solenoid "172"
or the valve solenoid "158".
With relay 177 the engine can also be
stopped with the ignition key.
The relays 151 and 151 b protect the en-
gine against re-start while engine is run-
ning.
The corresponding description of function
can be obtained from your HATZ service
agent.

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

Engine 1) with solenoid only


2) with glow plug only

Battery

121 Glow plug 159 Diode NOTE:


123 Glow controller 161 Temperature switch
124 Governor-rectifier 162 Oil pressure switch Additional monitoring devices
126 Alternator 173 Terminal distributor to the laid down engine contro
127 Starter 176 Blower control switch require prior contacts with
129 Charging indicator lamp 177 HATZ-Ruhstorf
151 Timing relay 181 Solenoid valve
157 Solenoid or 182 Glow starting switch
158 Fuel shut off solenoid