HATZ 2g30

LP8500 WORKSHOP MANUAL
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LP8500 Main Specs
ENGINE
Make Hatz
Model 2G40
Type 4 stroke diesel
BoreXstroke 3.62X2. 95“( 90X75mm)
Displacement 60.79 cu in (0.99 l)
Horsepower 13.1 KW (17.56 HP) @ 2500 RPM
Cooling air
HYDRAULIC SYSTEM
Propulsion system
Type Open circuit hydrostatic with one pump
and two motors in series per side.
Pump- Type Gear
Displacement 0.183 cu in/rev ( 3 cu cm/rev)
Motors Type Radial Pistons

Displacement 34.4 cu in/rev ( 565 cu cm/rev)
Two motors in series on each side
Control valve Type Solenoid actuated
Relief valve Setting 4060 PSI (28 MPa)
Brake valve Max Pressure 4500 PSI (31 MPa)

Pilot ratio 3.2:1
Vibration System
Type Open circuit hydrostatic
Pump Type Gear
Displacement 0.51 cu in/rev (8.4 cu cm/rev)
Motor Type Gear
Displacement 0.66 cu in/rev (10.8 cu cm/rev)
Relief valve Setting 2175 PSI (15 MPa)
Oil Cooler
By-pass Valve Setting 80 PSI (0.55 MPa)

ENGINE

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. Engine illustrations 3.1.1. Fuel pressure pipes
1.3. Type plate data 3.1.2. Injector
1.4. Modification survey 3.1.3. Injection pump
2. Additional equipment 3.2. External components
3.2.1. Cooling air duct
2.1. Fuel supply system 3.2.2. Oil filler
2.1.1. Fuel tank 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 2.4.5. Gearring 3.4.5. Conrod
2.5. Engine-monitoring system 3.5. Components, flywheel-side
2.5.1. Temperature switch 3.5.1. Oil pump
2.5.2. Oil-pressure switch 3.5.2. Flywheel
2.6. Power-take-off, mechanical 3.5.3. Timing cover
2.6.1. Stubshaft 3.6. Crankcase and internal
2.6.2. Flexible coupling components
2.6.3. Centrifugal clutch 3.6.1. Crankshaft
2.6.4. Power-take-off flange 3.6.2. Governor lever
2.7. Power-take-off, hydraulic 3.6.3. Camshaft and governor
2.7.1. Mounting parts for hydraulic pump 3.6.4. Crankcase
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
1.3. Type plate data
1) If required
2) In special cases only, e.g. engines acc. to Federal Authority for Automobilism.

1.2. 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-
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 -
- 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“.
- Visual inspection, especially for plane
contact surface.
- Maintenance work as per instruction
book.
Assembly:
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: -
- Release the hose clips „1”. - Unscrew the maintenance indicator „8”.
- Remove parts # „2” ... „6”.
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”.
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:
assembling.
- Connect the cable connection to the
electrical system.
Note the circuit diagram or wiring diag-
ram !
Chapt. 10.
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.
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 :
assembling.
- Chapt. 4.8.1.
- Connect the cable connections to the
- Chapt. 6.4.1.
electrical system.
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.
diagram !
Chapt. 10.
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:
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.
diagram !
Chapt. 10.
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.
- 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: -
- 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:
assembling.
- Connect the cable connection to the
electrical system.
diagram ! Chapt. 10.
- Refer to instruction book for further infor-
mation.
2G . . / 10.92
2.5.
2.5.1.
2.5.2.
2 2

2.6. Power-take-off mechanical
2.6.1. Stubshaft 2.6.2. Flexible coupling
-33- - 24 - 25 -
Preparations: – Preparations: -
- 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: - 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: –
- 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.
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.
Assembly:
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.

- 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:
Assembly:
- Chapt. 6.1. - Chapt. 4.1.
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
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
HATZ- or BOSCH-Service station only. If
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
- -

- Remove parts # „1" ... „14" Note the model version
- Remove the parts, dependent upon
Inspection/ Repair: version „19" ... „29” .
Assembly: - Visual inspection.
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
- -

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.
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.
Assembly: Chapt. 3.0.
assembling.
Note the model version and, if neces-
sary. contact your HATZ service agent!
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.
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.
Assembly:
Chapt. 3.0.
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.
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
Ø
d
C (Bumping
h
Utilization clearance)
A B C D
d h Ø 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.
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-

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 !
- 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”.
Chapt. 7.1.
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-

- 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“.
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.
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.
- 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”.
- 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
-
-
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.
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
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...
=
8 .5
~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
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 „26“and 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...
=
8 .5
~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:
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...
=
8 .5
~1
<
= 8211...
= 9110... 1

3.7.1. Replacing oil seal ring
(power-take-off side)
- 27 - + 2 metal lamellas
(thickness 0,05 mm)

Dismantling:
- Push out the leaking oil seal ring.
- 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.
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

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

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
- -
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

4.7. Crankcase
4.7.1. Crankcase bottom half 4.7.2. Crankcase top half
- 1 - 21 - 22 - -
- 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.
- 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

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 Ω x 100 / scale Ω
- Separate the stator „1“ and rotor „2“. Terminal ⊥ = black measurement lead
Terminal Ω = red measurement lead
Inspection: Short the measurement leads and set
- Visual inspection the pointer to full-scale deflection 0 Ω
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 Ω x 1 / scale Ω the coil has short circuit to ground). The
Terminal ⊥ = black measurement lead above checks must be conducted
Terminal Ω = 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 Ω 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... : 26°±0.5

>
= 8214... : 23°±0.5
>= 9110... : 26°±0.5

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... : 26°±0.5

>
= 8214... : 23°±0.5
>= 9110... : 26°±0.5

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" .
Chapt. 7.1.
- Tighten the clamping piece “7”
- Remove the rubber band „3” and fit the
cotter pin “4/1” .
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

- 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.
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 -.
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 -.
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

7.2.
7.2.1.
c d e
m k
i
h
g
f
a b
B
- 0.015
a = Ø 48.00 - 0.035 max. – ( )
 b = Ø 45.00
+ 0.065
+ 0.025 max. 45.10 ( )
In bolted condition !  + 0.065
 B = Ø 44.50 + 0.025 max. 44.60 ( )
c = Ø 12 H7 + 00.018 max. 12.10 ( )
- 0.010
d = Ø 12 - 0.020 max. 11.90 ( )
+ 0.025
e = Ø 40.67 0 max. 40.75 ( )
+ 0.025
f = Ø 12 0 max. 12.10 ( )
+ 0.018
g = Ø 18 H7 0 max. 18.10 ( )
+ 0.025
h = Ø 35 H7 0 max. 35.10 ( )
+ 0.018
i = Ø 12 H7 0 max. 12.10 ( )
+ 0.060
k = Ø 16 + 0.040 max. 16.10 ( )
+ 0.060
m = Ø 16 + 0.040 max. 16.10 ( )
2 G ../ techn.state 1.89

7.2.
7.2.2.
<
= 8211...
0
a = Ø 16 h6 - 0.011 min. 15.90 ( )
+ 0.003
b = Ø 16 + 0.011 min. 15.90 ( )
+ 0.018
a c = Ø 16 H7 0 max. 16.10 ( )
b f
e d = 9.00
c
e = 13.00
d
f = 21.00
+ 0.081
> 8212...
= a = Ø 16 + 0.007 min. 15.90 ( )
+ 0.027
b = Ø 19 0 max. –
+ 0.090
c = Ø 19 + 0.065 min. –
+ 0.155
d = Ø 16 + 0.105 max. 16.20 ( )
a
g
bc e = 12.00
e f
f = 15.00
e g = 22.00
d
h
i h = 33.75 - 34.20
i = 10 x 16 x 0.5

7.3.
7.3.1.
M22 x 1.5 b f d2 c a2 f
g b
a3
e
d1
b a a1 M18 x 1.5
+ 0.015 + 0.015
a = Ø 38.485 0 a = Ø 45.00 + 0.005 min. 44.95 Standard
+ 0.015
b = 58 x 38 x 0.2 / 0.3 Ø 44.50 + 0.005 min. 44.45 (-0.5 mm)
b = R 2.5
+ 0.70
c = 28.30 0 max. 29.10
+ 0.010
d = Ø 45.0 j6 + 0.006 min. 44.95 Standard
+ 0.010
Ø 45.5 j6 + 0.006 min. 44.45 (-0.5 mm)
e = siehe 3.6.1.
+ 0.10
f = 28.30 0 max. 28.50
0
g = Ø 38.0 h6 - 0.016 min. –
a, d // = 0.003 max. –
a, d O = 0.005 max. 0.05
a, d HRC = 54 - 60
a, d Ra = 0.4

7.4.
7.4.1.
a
b c
- 0.015
a = Ø 18.00 - 0.026 max. –
+ 0.10
b = Ø 18.00 + 0.07 max. 18.15 ( )
+ 0.20
c = Ø 18.00 + 0.10 max. 18.30 ( )
a d e c f c d g e b
+ 0.003

a = Ø 18 – 0.007 min. –
– 0.015
b = Ø 18 – 0.030 min. 17.90 ( )

– 0.020
c = Ø 35 – 0.033 min. 34.90 ( )
HRC = 59 - 61 d = 35.85 min. 35.60 ( )
e = 35.85 min. 35.60 ( )

– 0.020
f = 28.45 – 0.060 min. 28.30 ( )
+ 0.20
g = 22.00 0 min. 21.80 ( )

7.5.
7.5.1.
2 G 30 Ø 88.0 Ø 88.5 Ø 89.0

2 G 40 Ø 92.0 Ø 92.5 Ø 93.0
I I = 2.0 max. 2.30 ( )
II II = 2.0 max. 2.30 ( )
III
III = 3.5 max. 3.65 ( )
a = Ø 26.00 ++ 0.007
0.002 max. 26.05 ( )
a b
b = Ø 26.00 max. 25.95 ( )
I 2 G 30 88.0 x 2.0 88.5 x 2.0 89.0 x 2.0

II 88.0 x 2.0 88.5 x 2.0 89.0 x 2.0
III 88.0 x 3.5 88.5 x 3.5 89.0 x 3.5
2 G 40 92.0 x 2.0 92.5 x 2.0 93.0 x 2.0
92.0 x 2.0 92.5 x 2.0 93.0 x 2.0
92.0 x 3.5 92.5 x.3.5 93.0 x 3.5
a
I = 0.40 - 0.65 max. 1.0 ( )
a = II = 0.40 - 0.65 max. 1.8 ( )
III = 0.30 - 0.60 max. 1.8 ( )
b
+ 0.016
a = Ø 48 H6 0 max. –
+ 0.013
b = Ø 29 H6 0 max. –
d c + 0.043
c* = Ø 26 + 0.030 max. 26.25 ( )
d = 0.08 150 mm
a
e* = Ø 45.00 max. 45.10 ( )
M8 x 1 e
E* = Ø 44.50 max. 44.60 ( )
* In bolted or pressed-in condition !

7.6.
7.6.1.
2 G 30
Ø 88.0 + 0.01
0 max. 88.15 ( )
 AB
 C
+ 0.01
Ø 88.5 0 max. 88.65 ( )
A Ø 89.0 + 0.01
max. 89.15 (
0 ) D
Raµ = 0.9 - 1.3
B d = 0.5
C 2 G 40
D Ø 92.0
Ø 92.5
+ 0.01
0 max. 92.15 (
+ 0.01
) A
B
)  C

0 max. 92.65 (
Ø 93.0 + 0.01
0 max. 93.15 ( ) D

d Ra µ = 0.9 - 1.3
d = 0.5
P2
A
B
C
d1
D
d2
d4
d3
P1
P1 - P2 = 0.02 mm
d1 d2 d3 d4
A = 12 mm
B = 50 mm
C = 87 mm
D = 115 mm

7.7.
7.7.1.
+ 0.016
a = Ø 15 f6 + 0.027 min. 14.90 (
)
+ 0.018
b = Ø 15 H7 0
e d
c* = R10
c a
d = M8 x1
f
b d
c
e = 0.2 / 0.3
f e
f = 0.1 -
b
+ 0.006
e a = Ø 14 K7 – 0.012 max. –
c + 0.046
b = Ø 14 + 0.038 min. –
b
+ 0.009
a c* = Ø 8 H6 0 max. 8.05 (
d
)
d =7 + 0.2
e = 41.8
* In pressed-in condition only !
0
a = Ø 7.96 – 0.015 min. 7.85 (
a )
b 0
b = Ø 7.97 – 0.015
c min. 7.85 (
d c
e c = 45° )
d = Ø 37
a a
e = Ø 33
a = 0.9 - 1.5

7.8.
7.8.1.
b
d
0
a = 29.77 – 0.025 min. 29.70 ( )
– 0.060
b = 18.00 – 0.080 min. 17.89 ( )
0
c = 40.576 – 0.025 min. 40.45 ( )
0
d = 30.060 – 0.030 max. 30.10 ( )
Axial play: 0.01 - 0.05 mm New parts

max. 0.10 mm Wear limits

8. Governor - injection system

8.1.
8.1.1.
KBEL 65 S 49 PFR 2K 60A 
⇐⇐
478

PFR 2K

Ø 1.8 mm
DLLA 159S 1082 250 +8 bar
>
= 8210 ...
⇐
2 G 30 >= 8214 ... 2 G 40 >= 9110 ...

0.1 / 0.2 / 0.3
mm
98.5 ± 0.8 mm
Ø 1.5 mm
DLLA 159S 1141 250 +8 bar

8.2.
8.2.1.
n (min
-1
) applic. L (mm) d (mm)
≤ 3000 min-1 1500 Gen. 17.5 0.7
≤ 2300 univers. 17.5 0.8
2300 17.0 1.0

– 3000 univers. 17.5 1.0
17.0 1.0
3000 Gen. 17.5 1.0
8.3.
8.3.1.
26° ± 0.5 >= 8213 ...
23° ± 0.5 >= 8214 ...

9110 ...
26° + 0.5 = 2 G 40 - 151.

(MACO-MEUDON)

9. Special tools / sealants and
bonding agents

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
1 1D . . / 04.03
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
1D . . / 04.03 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

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 ϑ 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
ϑ 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

HYDRAULIC SYSYTEM

1
LP8500 HYDRAULIC SYSTEM
The Hydraulic system of the LP850 consists of a hydraulic tank, a triple gear pump, a
valve block, four propulsion motors (two for left propulsion, and two for right propulsion
565 cc/rev=34.5 cu in/rev), one vibration motor, a hydraulic cooler, a hydraulic cooler
by-pass valve (.55 Mpa=80 PSI), a return filter (by-pass at 0.17Mpa=25 PSI) and a
hydraulic tank breather (.035Mpa=5 PSI).
Built in the valve block there are the main solenoid valve (Y10), the propulsion relief
valve (28 Mpa=4060 PSI), the vibration relief valve (15 Mpa=2175 PSI), the high speed
solenoid valve (Y9), the left propulsion solenoid control valve (Y3 & Y4) the left
propulsion brake valves (10Mpa=1450 PSI), the right propulsion solenoid control valve
(Y5 & Y6), the right propulsion brake valves (10 Mpa=1450 PSI), and the vibration
solenoid control valve (Y7 & Y8), and four check valves.
There are two test ports, M1 for the vibration circuit and M2 for the propulsion circuits.
One section (8.4cc/rev =0.51 cu in/rev) of the pump feeds the vibration circuit entering
theva lvebl ockt hr oug hpor t“P1” ,asec onds ection( 3cc/rev=0.18c ui n/ r
ev)f eedsthe
leftpr op ulsi
onc ircui tenteringt heva l
vebl oc kthr oug hpor t“P”,andat hi r
ds ection
(3cc/.rev= 0.18 cu in /rev) feeds the left propulsion circuit entering the valve block
throug hpor t“P2” .
When the main solenoid valve (Y10) is de-energized the pumps flow for the propulsion
circuits return to the tank free through that valve. In order to be able to operate the
propulsion circuits, the main solenoid valve must be energized, to close the passage to the
tank.
To operate propulsion, one of the solenoids of the propulsion control valve must be
energized. When solenoid Y6 of the right propulsion solenoid control valve is energized,
the valve spool shifts, and opens a passage for the pump oil flow to go to the rear motor
through the check valve of the brake valve. Since the two motors are connected in series,
the oil flows first to the rear motor and after that to the front motor, and from the front
motor returns to the tank through the control valve. The brake valve blocks the oil
flowing out of the front motor until pressure on the oil flowing to the rear motor opens
the brake valve.
When solenoid Y6 is de-energized, the control valve spool moves to the neutral position,
shutting off the pump flow to the motors. Due to the inertia of movement of the machine,
the motors have a tendency to keep turning and start working as pumps, pumping oil to
the return, but the brake valve has closed and a very high pressure is needed to open that
valve by the oil flowing out of the motors, what slows down and stops the motors very
quickly.
When the high-speed valve (Y9) is de-energized, the vibration pump flow feeds the
vibration solenoid control valve.
When the high-speed valve is energized, it diverts the vibration pump flow to the
propulsion circuits increasing the sped of the propulsion motors (High speed). Since the
vibration pump flow is diverted to the propulsion circuits, no vibration is possible when
the high-speed valve is energized.

Group 2
Gear Pumps and Motors

Service Manual

Gear Pumps and Motors Group 2
1. Introduction
1.1 Using This Manual
The purpose of this manual is to provide useful to change the rotation of the pump or motor. The
information concerning assembling and disassem- appendix gives information on testing and relative
bling of Group 2 pumps and motors. In order to obtain specifications. A list follows including the special
the maximum performance from this series of com- tools necessary for the operations described in the
ponents, we recommend special attention be given previous sections.
to the suggestions and recommendations included. This manual gives only general procedures for ser-
vicing and does not give part numbers of single
products or single components. If this information is
This manual gives a general description of the design required, please contact Sauer-Danfoss.
of the units. It also details disassembling and assem-
bling procedures for single units (pumps and mo- All of the information contained in this manual is
tors). It then follows-up with the multistage units, accurate at the date of printing. Sauer-Danfoss
explaining how to combine or separate into single reserves the right to change any specifications with-
stages. A special section is devoted to describe how out prior notice.
1.2 Safety Precautions
Always consult the equipment’s operator manual for Disable Work Function
specific safety warnings prior to approaching a ma-
chine. Hydraulic components may be located in
WARNING
close proximity to sharp and/or hot components;
always take appropriate precautions.
Certain service procedures may require the
Flammable Cleaning Solvents vehicle/ machine to be disabled while perform-
ing them in order to protect the technician and
bystanders.
WARNING
Some cleaning solvents are flammable. To re-

duce risk of fire, do no use cleaning solvents in an Fluid Under High Pressure
area where a source of ignition may be present.
WARNING
Personal Safety
Use caution when dealing with hydraulic fluid

WARNING under pressure. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin causing serious injury. This fluid may
Proper safety equipment, including safety glasses, also be hot enough to burn. If cut or burned by
should be used at all times. hydraulic fluid, seek proper medical attention
immediately.
Copyright 1999, Sauer-Danfoss Company.

All rights reserved. Contents subject to change. Printed in U.S.A. 0599H

Contents
1. Introduction ................................................................................................................................................ 2
1.1 Using This Manual ............................................................................................................................... 2
1.2 Safety Precautions .............................................................................................................................. 2
1.3 Symbols Used in Sauer-Danfoss Literature ......................................................................................... 5
2. General Information ................................................................................................................................... 6
2.1 General Description .................................................................................................................................... 6
2.2 Design ................................................................................................................................................. 7
2.3 Model Code ......................................................................................................................................... 8
3. Technical Specifications ...........................................................................................................................10
3.1 Hardware Specifications ............................................................................................................................10
3.2 System Specifications .......................................................................................................................11
3.3 Fluids and Filtration ............................................................................................................................11
4. Servicing ....................................................................................................................................................12
4.1 Conversions .......................................................................................................................................12
4.1.1 Recommendations .......................................................................................................................12
4.2 Conversion Tables ..............................................................................................................................12
5. Disassembly ..............................................................................................................................................14
5.1 General ..............................................................................................................................................14
5.1.1 Cleanliness ..................................................................................................................................14
5.1.2 Lubrication of Moving Parts .........................................................................................................14
5.1.3 Care of Surface Treatment ...........................................................................................................14
5.1.4 Marking the Parts ........................................................................................................................14
5.1.5 Procedure ....................................................................................................................................15
6. Assembly ...................................................................................................................................................19
7. Multi Stage Pumps ....................................................................................................................................27
7.1 General ..............................................................................................................................................27
7.1.1 Construction ................................................................................................................................27
7.2 First Stage Pump Preparation ............................................................................................................28
7.2.1 General ........................................................................................................................................28
7.2.2 Model Code .................................................................................................................................28
7.2.3 Converting a Single Stage Pump to a First Stage Pump ..............................................................29
7.2.4 Conversion Procedure ..................................................................................................................29
7.3 Intermediate Stage Pump Preparation ................................................................................................30
7.3.1 General ........................................................................................................................................30
7.3.2 Model Code .................................................................................................................................30
7.3.3 Converting a Single Stage Pump to an Intermediate Stage Pump ...............................................31
7.4 Final Stage Pump Preparation ............................................................................................................32
7.4.1 General ........................................................................................................................................32
7.4.2 Model Code .................................................................................................................................32
7.4.3 Converting to a Rear Stage Pump ...............................................................................................33
7.5 Assembly of Multi-Stage Pumps ........................................................................................................34
7.6 Change of Rotation ......................................................................................................................35
7.6.1 General ........................................................................................................................................35
7.6.2 Determining the Direction of Rotation ...........................................................................................35
7.6.3 Model code ..................................................................................................................................36
7.6.4 Conversion procedure ..................................................................................................................36

8. SKP2 Pumps ............................................................................................................................................. 39
8.1 General Information ............................................................................................................................ 39
8.1.2 Drive Gear Shaft Differences ....................................................................................................... 40
8.1.3 Front and Rear Flange Differences ...............................................................................................40
8.1.1 Bearing Block For SKP2 ..............................................................................................................40
8.1.4 Bearing Block Differences ...........................................................................................................41
8.2 Changing the Rotation of SKP2 .......................................................................................................... 42
9. Product Options ....................................................................................................................................... 44
9.1 Rear Cover with Integral Priority Flow Divider Valve ............................................................................ 44
9.1.1 General Information ..................................................................................................................... 44
9.1.2 Disassembly and Reassembly ..................................................................................................... 44
9.2 Rear Cover with Integral Relief Valve ..................................................................................................45
9.2.1 General Information ..................................................................................................................... 45
9.2.2 Disassembly and Reassembly ..................................................................................................... 45
10. Trouble Shooting ..................................................................................................................................... 46
10.1 Low or No Flow From Gear Pump ................................................................................................ 46
10.2 Excessive Noise ..........................................................................................................................46
10.3 External Leakage ......................................................................................................................... 46
11. Appendix ..................................................................................................................................................48
11.1 Stud Specifications ............................................................................................................................ 48
11.2 Stud Length For Multi-Stage Pumps ................................................................................................... 48
11.2.1 Tandem Pumps ............................................................................................................................ 48
11.2.2 Multi-Stage Pumps (General Rule) ...............................................................................................49
11.2.3 Component Lengths ..................................................................................................................... 49
11.3 Testing the Pumps and Motors ...........................................................................................................50
11.3.1 General ........................................................................................................................................ 50
11.3.2 Test Procedure .............................................................................................................................50
11.3.3 Tables .......................................................................................................................................... 50
11.3.3 Tables (cont.) ............................................................................................................................... 51
11.4 Tools ............................................................................................................................................52
11.4.1 Shaft Seal Installation Tool ...........................................................................................................52
11.4.2 Shaft Seal Protective Sleeves .....................................................................................................53
11.5 Shaft Dimensions ............................................................................................................................... 54
11.5.1 Shafts Used with 01 Flange ......................................................................................................... 54
11.5.2 Shafts Used with 02 Flange ......................................................................................................... 56
11.5.3 Shafts Used with 04 / 05 Flange ..................................................................................................57
11.5.4 Shafts Used with 06 Flange (SAE) ............................................................................................... 58
11.5.5 FR Tang Shaft .............................................................................................................................. 60
11.5.6 Mating Design for FR03 Pumps ................................................................................................... 60
11.6 Flange Types ......................................................................................................................................61

1.3 Symbols Used in Sauer-Danfoss Literature

DANGER! May result in injury. Lubricate with hydraulic fluid.
May result in immediate or premature damage. Apply grease/petroleum jelly.
Reusable part. Apply locking compound.
Nonreusable part, use a new part. Inspect for ware or damage.
Non-removable item. Clean area or part.
“OR” in drawing - either option may exist. Be careful no to scratch or damage
Measurement required. Note correct orientation.
Flatness specification. Mark orientation for reinstallation.
Parallelism specification. Torque Specification.
External hex. Press in.
Internal hex. Pull out with tool.
Torx head. Use installation sleeve/cone (bullet).
P101 128 P101 129

2. General Information
2.1 General Description
Group 2 gear products consist of pumps, reversible Generally, all these products follow the same proce-
pumps, uni- and bidirectional motors. This group of dures for assembling, disassembling, and servicing.
gear pumps and motors is characterized by a wide In this manual, the SNP2 will be used as an example
selection of components. It is possible to have a wide for all unidirectional pumps and motors (SNP/SEP/
range of units resulting from a common base of SHP/SNU 2), and the SNM2 for all the bi-direction
components or processes. This manual describes pumps and motors (SNM/SEM/SNR/SHM 2). SKP
the service procedures that can be applied to all the assembly and disassembly information will be handled
products of this range. The complete range of in a separate section of this manual.
products detailed in this manual are:
• SNP 2 Standard gear pump
• SEP 2 Gear pump, similar to SNP2, without
DU-Bushings (Cost Effective Model)
• SHP 2 Gear pump, similar to SNP2, with
longer shaft journal bearings
(high performance model)
• SKP 2 Gear pump, similar to SNP2, with
larger shaft specially designed to
accommodate SAE 11 tooth spline
• SNU 2 Unidirectional gear motor, similar to
SNP2 pump
• SNM 2 Standard bidirectional gear motor
• SEM 2 Bidirectional gear motor, similar to
SNM2, with lower pressure limits
(Cost effective model)
• SNR 2 Bidirectional gear pump.
• SHM 2 Bidirectional gear motor, similar to
SHP2 pumps, with longer shaft
journal bearings, and higher
pressure rating than SNM2

2.2 Design
Snap Ring
Shaft Seal
Outer Seal
Bearing Block Assembly
Drive Gear
Body (Housing)
Rear Cover
Pressure Seal
Front Flange
Teflon Backup Ring
Dowel Pin Idler Gear
Capscrew
P101 130

2.3 Model Code
ABCD E F H L M N P R S
/
Type
SNP 2 = Standard Gear Pump
SKP 2 = High Torque Gear Pump
SHP 2 = High Pressure Gear Pump
SNI 2 = Gear Pump with Internal Drain Relief Valve
SNE 2 = Gear Pump with External Drain Relief Valve
Valve (omit when not used)
U = Priority Flow Divider with Pilot Relief Valve
L = Priority Flow Divider with Pilot Relief Valve and Static Load Sensing
N = Priority Flow Divider with Pilot Relief Valve and Dynamic Load Sensing
P = Priority Flow Divider with Full Flow Relief Valve
F = Priority Flow Divider with Full Flow Relief Valve and Static Load Sensing
V = Priority Flow Divider with Full Flow Relief Valve and Dynamic Load Sensing
Valve Port Position (omit when not used)
S = Side Ports
R = Rear Ports
Displacement
cm3/rev / [(in3/rev]
4 = 3.9 / [0.24]
6 = 6.0 / [0.37]
8 = 8.4 / [0.51]
11 = 10.8 / [0.66]
14 = 14.4 / [0.88]
17 = 16.8 / [1.02]
19 = 19.2 / [1.17]
22 = 22.8 / [1.39]
25 = 25.2 / [1.54]
Direction of Rotation
D = Right (Clockwise)
S = Left (Anti-clockwise)
Input Shaft / Mounting Flange / Port Configuration
CO Tapered shafts, 1:5 or 1:8
CO01 = 1:8 tapered shaft / European four bolt flange / European flanged ports
CO02 = 1:5 tapered shaft / German four bolt PTO flange / German standard ports
CO04 = 1:5 tapered shaft / German two bolt PTO flange (Deutz) / German standard ports
CO05 = 1:5 tapered shaft / German two bolt PTO flange (Deutz) / German standard ports
CO09 = 1:8 tapered shaft / Perkins 4.236 timing case flange / European flanged ports
CO09 = (variant BBM) 1:8 tapered shaft / Perkins 900 series flange / German standard ports
CO0B = 1:8 tapered shaft / Perkins 1000 series left side PTO flange / European flanged ports
CO91 = (variant LBD) 1:8 tapered shaft / European four bolt flange / European flanged ports / equipped with outrigger bearing
CO94 = 1:5 tapered shaft / German two bolt PTO flange (Deutz) / German standard ports / equipped with outrigger bearing
CI Parallel shafts, 15mm or 15.875mm
CI01 = 15mm [.591 in] parallel shaft / European four bolt flange / European flanged ports
CI06 = 15.875mm [.625 in] parallel shaft / SAE "A" flange / SAE O-ring boss ports
CI96 = (variant LEP) 19.05mm [.750 in] parallel shaft / SAE "A" flange / SAE O-ring boss ports / equipped with outrigger bearing
SC Splined shafts, DIN B17x14, SAE 9T 16/32p, or SAE 11T 16/32p (SKP 2 only)
SC01 = DIN splined shaft / European four bolt flange / European flanged ports
SC02 = DIN splined shaft / German four bolt PTO flange / German standard ports
SC04 = DIN splined shaft / German two bolt PTO flange (Deutz) / German standard ports
SC05 = DIN splined shaft / German two bolt PTO flange (Deutz) / German standard ports
SC06 = SAE splined shaft / SAE A flange / SAE O-ring boss ports
SC36 = SAE splined shaft / SAE A flange plus SAE A auxiliary mounting pad / SAE O-ring boss ports
FR Sauer-Danfoss tang shaft
FR03 = Sauer-Danfoss tang shaft / flanged for multiple configuration / German standard ports

ABCD E F H L M N P R S
/
Variant Code (Three letter code describes valve settings or other variants to standard configuration)
BBM = Variation on 09 flange to accommodate Perkins 900 series engine mounting
LEP = Variant on standard straight shaft used with CI96 outrigger bearing option.
LBD = Variant on standard tapered shaft used on CO91 outrigger bearing option.
U∗∗∗∗ Integral flow divider
Pressure setting at controlled flow [bar] / (psi)
L = [60] (870) T = [140] (2030)
M = [70] (1015) C = [150] (2175)
N = [80] (1160) U = [160] (2320)
O = [90] (1305) D = [170] (2465)
P = [100] (1450) V = [180] (2611)
Q = [110] (1595) E = [190] (2755)
R = [120] (1740) X = [200] (2901)
S = [130] (1885)
Controlled flow [l/min] / (US gal/min)
M = [8] (2.11) J = [18] (4.75)
F = [10] (2.64) Q = [20] (5.28)
N = [12] (3.17) K = [22] (5.80)
O = [14] (3.70) R = [24] (6.34)
P = [16] (4.23) I = [26] (6.86)
V∗∗∗∗ Integral relief valve
Pressure setting [bar] / (psi)
A = No setting O = [90] (1305)
B = No valve P = [100] (1450)
C = [18] (261) Q = [110] (1595)
D = [25] (363) R = [120] (1740)
E = [30] (435) S = [130] (1885)
F = [35] (508) T = [140] (2030)
G = [40] (580) U = [160] (2320)
K = [50] (725) V = [170] (2465)
L = [60] (870) W = [180] (2611)
M = [70] (1015) X = [210] (3045)
N = [80] (1160) Z = [250] (3626)
-1
Pump speed for relief valve setting (min (rpm))
A = Not defined
C = 500
E = 1000
F = 1250
G = 1500
K = 2000
I = 2250
L = 2500
M = 2800
N = 3000
O = 3250
Version (Value representing a change to the initial project)
. = Initial project
1..9 A..Z = Reserved to
Port Type (If other than standard)
. = Standard port for the flange type specified
B = Flanged port with threaded holes in "X" pattern (German standard ports), centered on the body
C = Flanged port with threaded holes in "+" pattern (European Standard)
E = Threaded SAE o-ring boss port
F = Threaded Gas port (BSP)
G = Flanged port with threaded holes in "X" pattern (German standard ports), offset from center of body

3. Technical Specifications
3.1 Hardware Specifications
Pump Model 4 6 8 11 14 17 19 22 25
3
cm /rev 3.9 6.0 8.4 10.8 14.4 16.8 19.2 22.8 25.2
Displacement
[in3/rev] [0.24] [0.37] [0.51] [0.66] [0.88] [1.02] [1.17] [1.39] [1.54]
SNP
bar 280 280 280 280 280 280 230 200 175
Peak Pressure
[psi] [4060] [4060] [4060] [4060] [4060] [4060] [3335] [2900] [2538]
bar 250 250 250 250 250 250 210 180 160
Rated Pressure
[psi] [3625] [3625] [3625] [3625] [3625] [3625] [3045] [2610] [2320]
min-1
Minimum Speed at 0-100 bar (rpm) 600 600 600 500 500 500 500 500 500
min-1
Minimum Speed at min-1
180 bar to rated pressure (rpm) 1400 1400 1400 1200 1000 1000 1000 - -
min-1
Maximum Speed (rpm) 4000 4000 4000 4000 3500 3000 3000 3000 3000
SK P
bar 280 280 280 280 280 280 260 230 200
Peak Pressure
[psi] [4060] [4060] [4060] [4060] [4060] [4060] [3770] [3335] [2900]
bar 250 250 250 250 250 250 240 210 190
Rated Pressure
[psi] [3625] [3625] [3625] [3625] [3625] [3625] [3480] [3045] [2755]
min-1
min-1
180 bar to rated pressure (rpm) 1400 1400 1400 1200 1000 1000 1000 800 800
min-1
Maximum Speed (rpm) 4000 4000 4000 4000 3500 3000 3000 3000 3000
SH P
bar 260 230 200
Peak Pressure
[psi] [3770] [3335] [2900]
bar 240 210 190
Rated Pressure
[psi] [3480] [3045] [2755]
min-1
Minimum Speed at 0-100 bar (rpm) 600 600 600
min-1
Minimum Speed at 100-180 bar (rpm) 800 800 800
180 bar to rated pressure (rpm) 1000 1000 1000
min-1
Maximum Speed (rpm) 3000 3000 3000
ALL The data below represent mean values for standard configured pumps.
kg 2.3 2.4 2.5 2.7 2.9 3.0 3.1 3.2 3.3

Weight
[lb] [5.1] [5.3] [5.5] [5.8] [6.3] [6.5] [6.7] [7.0] [7.3]
Moment of Iner tia of x10-6 kg m2 20.6 25.7 31.5 37.3 45.9 51.7 57.5 66.2 72.0
rotating components [x10-6 lbf ft2] [489] [610] [747] [885] [1089] [1227] [1364] [1571] [1709]
Theoretical Flow at l / min 15.6 24.0 33.6 43.2 50.4 50.4 57.6 68.4 75.6
Maximum Speed [US gal / min] [4.12] [6.34] [8.87] [11.4] [13.3] [13.3] [15.2] [18.0] [20.0]
T101 000E
10

3.2 System Specifications

Inlet Pressure Temperature
bar absolute °C °F
Recommended Range 0.8 to 3.0 Minimum (cold star t) -20 -4
Minimum (cold star t) 0.6
Maximum Continuous 80 176
T101 001E
Peak (Intermittent) 90 194
T101 001E
T101 003E
T101 003E
Fluid Viscosity -mm2/s (cSt) [SUS] Fluid Cleanliness Level and βx-Ratio
Required Fluid Cleanliness Level
Minimum 10 [60] Class 18/13 or better
(per ISO 4406)
Recommended βx-Ratio
Recommended Range 12 to 60 [66 to 290] β35-45 = 75 β10 ≥ 2
(Suction Filtration)
Maximum (cold star t) 1600 [7500] Recommended βx-Ratio
β15-20 = 75 β10 ≥ 10
(Pressure or Return Filtration)
T101 002E
Recommended Inlet Screen Size
100 µm-125 µm
(for Pressure or Return Filtration)
T101 004E
T101 004E
3.3 Fluids and Filtration
To prevent premature wear, it is imperative that only Filters are selected to meet these requirements
clean fluid enter the pump and hydraulic circuit. A using rating parameters of efficiency and capacity.
filter capable of controlling the fluid cleanliness to Filter efficiency may be measured with a Beta ratio1
Class 18/13 per ISO 4406 or better under normal (βX). For suction filtration, with controlled reservoir
operating conditions is recommended. ingression, a filter with β35-45 >= 75 (and β10 >= 2) or
better has been found to be satisfactory. For return or
The filter may be located on the pump outlet (pres- pressure filtration, filters with an efficiency of
sure filtration), inlet (suction filtration), or the reser- β15-20 >= 75 (and β10 >= 10) are typically required.
voir return (return line filtration).
Since each system is unique, the filtration require-
The selection of a filter depends on a number of ments for that system will be unique and must be
factors including the contaminant ingression rate, determined by test in each case. Filtration system
the generation of contaminants in the system, the acceptability should be judged by monitoring of proto-
required fluid cleanliness, and the desired mainte- types, evaluation of components, and performance
nance interval. Contaminant ingression rate is deter- throughout the test program.
mined (among other things) by the type of actuators
used in the system. Hydraulic cylinders normally See Sauer-Danfoss publications BLN-9887
cause higher levels of contamination to enter the [697581] and ATI-E 9201 for more information.
system.
(1) Filter βx ratio is a measure of filter efficiency defined by
ISO 4572. It is defined as the ratio of the number of particles
greater than a given diameter (“x” in microns) upstream of the
filter to the number of these particles downstream of the filter.
11

4. Servicing
4.1 Conversions
Group 2 is a modular series. In particular, it is easy
to make conversions on the pumps, e.g. changing
rotation, replacing flange, drive shaft, seals, or
assembling a tandem pump from two single pumps.
On the following page are tables showing the
allowable conversions.
4.1.1 Recommendations
Due to a specific manufacturing process known • Conversions should be limited to changing

as cut-in — during which the gears, pump body, the rotation, changing the seal kit, and replac-
and bearing blocks are allowed to establish a ing the flange and rear cover. Changing the
unique relationship to each other — it is gener- gear set is not advisable. When this operation
ally not recommended to open and replace com- cannot be avoided special care must be taken.
ponents of a gear pump or motor. The removal
or replacement of some internal components • Whenever possible avoid making conversions
will unavoidably modify their critical dimensions. to gear motors, as the critical dimensions are
Because pumps and motors are cut-in at a spe- more sensitive to minor changes.
cific pressure to ensure maximum efficiency,
• Always use new, factory supplied parts when
removal or replacement of internal components
making a conversion.
may be detrimental to the pump or motor effi-
ciency. Pump / motor conversions are allowed if
• After any conversion, it is recommended that
the following criteria are followed. The following
the unit be tested on a suitable test stand in
is a list of general recommendations.
order to confirm its performance.
• The personnel performing any type of conver-
sion must be trained. The performance of a • Reference the conversion tables given on the
converted unit is in direct relationship with the next page to ensure the operation is allowed.
quality of the job. A trained, qualified techni-
cian, by following the procedures in this manual,
should be able to perform a quality job.
4.2 Conversion Tables

The tables on the following page summarize the
conversion operations which are allowed. For any
unit component, the table shows the possibility of a
conversion operation (from one pump to another
pump, from one motor to another motor, from pump
to motor, and from motor to pump.) For SKP, the only
conversion allowed is from pump to pump.
12

Component Conversion Operation

YES = Allowed
NO = Not Allowed From From From From
N.R. = Allowed but not Pump to Pump Motor to Motor Motor to Pump Pump to Motor
recommended
Body NO NO NO NO
Bearing N.R. NO NO NO
Front Flange YES YES NO NO
Rear Flange (Tandem) YES ---- ---- NO
Cover YES YES NO NO
Drive Gear YES YES YES NO
Idle Gear YES YES YES NO
Pressure Seals YES YE S NO NO
Outer Seal YES YES YES YES
Shaft Seals YES YES YES YES
Snap Rings YES YES YES YES
Dowel Pins YES YES YES YES
Bolts YES YES YES YES

T101 135E
The following conversion steps are allowed on the

product groups listed below.
Conversion SNP 2 SNU 2 SEM 2 SNM 2 SKP 2 SHM 2
Rotation YES YES NO NO YES NO
Input Shaft YES YES YES YES YES YES
Rear Cover YES NO NO NO YES NO
Flow Setting YES NO NO NO YES NO
Pressure Setting YES NO NO NO YES NO
Front Flange YES YES YES YES YES YES
Displacement YES YES YES YES YES YES
Mulitple Pumps YES NO NO NO YES NO

T101 136E
13

5. Disassembly
5.1 General
In the following pages a detailed procedure is given
for disassembly and assembly of pumps and motors.
Prior to proceeding it may be necessary to prepare
some subassemblies separately.
The details for preparing each subassembly are

given in the following section.
Also, some general recommendations are given below.
5.1.1 Cleanliness 5.1.3 Care of Surface Treatment
Cleanliness is a primary factor for reliable Be careful when handling all the internal
pump performance. Wash the outside of the pump surfaces, especially bearings, gears, and body faces.
thoroughly before disassembly and all pieces prior to Do not touch or score them with metal tools or cutting
assembly. Cleaning parts with clean shop solvent edges.
and air drying is usually adequate.
5.1.4 Marking the Parts
5.1.2 Lubrication of Moving Parts
Mark the parts before completely disassem-
During assembly, it is imperative to provide bling a pump. The marks allow components to be
lubrication with clean hydraulic oil to all the running reassembled in the same relative position. This ac-
parts of the pump. tion should be applied to the body, bearings, and
gears. Scribing, bluing, or using a felt tip pen to mark
It is also necessary to coat the seals with the outside of the body on the inlet side is suggested
grease. The absence of lubrication during assembly to indicate the relative position of the front flange and
can cause the unit to seize after a few minutes of the rear cover to the body. Mark the bearing blocks
running. also on the inlet side and the gears position relative
to each other. DO NOT scribe internal surfaces.
14

5.1.5 Procedure
1. Clamp the unit.

Clamp the unit in a vice from the flange side.
Make sure the vice jaws are clean and have

smooth surfaces to prevent damage to the pump.
Clamping the pump on the body is not recommended

because serious damage to the surfaces, on which
the ports are located, may occur.
F101 000
2. Remove capscrews.
(Except Units with 03 Flange)
Use a 17 mm socket wrench and loosen the

four capscrews on the cover. Next completely un-
screw the capscrews and remove them.
Inspect the threads of the capscrews for

damage.
F101 001
06 Flange (first stage of multiple pump) 3. Remove socket head capscrews.

(03 Flange or Multiple Pump Stages Only)
Using a 4 mm internal hex wrench, loosen

and remove the two small socket screws placed in
the center of the cover. Repeat the same operation
for the corresponding screws on the rear flange.
Socket Screws
03 Flange
F101 002
15

4. Remove front flange.

Place the pump on the table and slowly remove the
front flange.
Be careful not to damage the shaft seal when

removing the flange. Avoid contact of the shaft seal
lips with keyway edges (in tapered and parallel
shafts) or splined shaft teeth.
Inspect the front flange and seal area.
Clean with shop solvent, dry, and set aside.
F101 003
5. Remove rear cover.

Remover rear cover.
Clean with shop solvent, dry, and set aside.
Visually inspect rear cover and seal area.
F101 004
16

6. Remove bearing blocks and gears.

Place the pump on its side and carefully remove
the bearing block and gear set. To accomplish
this, hold the pump body and push with your
fingers on the rear bearing block.
Mark the relative positions of the gear

mesh (drive gear tooth to idler gear tooth) and the
bearing blocks to the body so they can be reas-
sembled in the same position.
F101 005
7. Remove pressure seals.

• For SNP 2/SNU 2/SEP 2/SHP 2
Check the seal quality. Replacement is

recommended whenever there are burrs, evidence
Teflon Backup Ring
of extrusion, or marks caused by overheating. If
the seals need to be replaced, carefully remove
them from the flange cover, beginning with the
backup ring and then the pressure seal.
Pressure Seal
Important: Do not use tools with sharp
edges to remove the seals, as damage to the
cover can result.
F101 006
After removal, dispose of damaged seals.
• For SNM 2/SEM 2/SHM 2/SNR 2 Motors
Follow the same recommendations given for the

previous item. If it is necessary to remove the seals,
pay close attention to this procedure. Do not force
the removal of the backup ring, remove it gradually
to avoid damaging the groove in the flange.
The pressure seal is very delicate, handle it with care.
Pressure Seal After removal, dispose of damaged seals.

Backup Ring cover can result.
F101 007
17

8. Remove Outer O-Ring Seal
Check the quality of this seal. If necessary,

replace it. Follow the same removal recommenda-
tions given in step 7.
After removal, discard the damaged seal.

cover can result.
O-Ring
F101 008
9. Remove the snap ring.

Place the flange on the work surface. Using internal
snap ring pliers, remove the snap ring.
F101 009
10. Remove the shaft seal.
Check the shaft seal quality and remove if

necessary.
To remove, pry the bottom of the shaft

seal and force it out while rotating the flange to lift
it out evenly.
Do not use the flange pilot to gain leverage,

damage may result. Use a plastic rod or wooden
dowel as a fulcrum.
After removal, dispose of damaged seal.
F101 010
18

6. Assembly
1. Prepare the seals.
Have the entire seal kit available.
Lightly coat all seals with seal grease. The

grease is needed to adhere the seals to their grooves.
Do not install dry seals.
F101 011
2. Install shaft seal into front flange.
Prepare the flange and shaft seal by lightly

lubricating with grease.
Seat the seal in the flange by hand. Then,

using the shaft seal installation tool (shown on
page 52), press the seal until the tool stops on the
flange. This will insure the seal is inserted to the
proper depth.
F101 012
3. Install snap ring.

Install the snap ring using internal snap ring pliers.
Ensure the snap ring fits securely in its groove. This
is necessary to retain the shaft seal.
F101 013
19

4. Install pressure seals.
• Pumps and Uni-Directional Motors
Prepare the pressure seals by lightly lubri-

cating them with grease.
Install pressure seals into the grooves on the front

flange and rear cover. Then install the teflon
backup ring. Teflon Backup Ring
Ensure that the seals are located in the grooves,

as shown.
Pressure Seal
F101 014
• Bi-Directional Motors
Prepare pressure seals by lightly lubricating

them with grease.
Install pressure seals into the grooves on the front

flange and rear cover. Then install the teflon
backup ring.
The backup ring will fit tightly into the groove. Work
the backup ring into the groove by hand. Begin with
Pressure Seal
the internal portion of the seal, then proceed outward
until the backup ring is securely pressed into place.
Backup Ring
F101 007
5. Prepare the body.
Clean the body.
Inspect the internal and mating surfaces.

Ensure the surfaces are free of burrs and scratches.
Check both the bearing block mating surface and the
cut-in path. The cut-in path should be no deeper than
0.1 mm (0.004 in).
F101 016
20

6. Install outer seal.
Prepare the outer seal by lightly lubricating

with grease.
Install outer seals in the grooves on both sides of

the body.
F101 017
7. Prepare the gears.
Caution: The gear surfaces are superfin-

ished. Residue on hands and fingers may be corro-
sive to this surface. Do not touch.
Carefully clean the two gears. If the gears

are new, wash them with shop solvent to remove any
anticorrosive grease on the surfaces.
Inspect the journals and the flat faces on

the top and bottom of the gears. Ensure these
surfaces are free from burrs or scratches. If
scratches or burrs are found, clean them with a flat
stone and/or very fine emery paper. Rewash the
gears after this operation.
F101 018
8. Prepare the bearing blocks.
Clean the two bearing blocks.
Inspect the flat surfaces of the bearing

blocks for burrs or scratches on the edges. If
necessary, remove burrs with very fine emery
paper. Then rewash the bearings.
Inspect the DU™ bushings for wear. There

should be no bronze showing.
Using clean hydraulic oil, lubricate the inter-

nal and external surfaces of the bearing blocks.
F101 019
21

9. Assemble the bearing blocks and gears.
Lubricate the journals and the gear faces.
Assemble the bearing blocks and gears.

Ensure that the recessed bearing faces are installed
adjacent to the gear faces. Align all assembly marks
made during disassembly. Ensure the front and rear
bearing blocks occupy the same location with re-
spect to the housing as before disassembly. Ensure
that the relative position of the gear mesh is main-
tained as before disassembly. Misalignment of the
gear teeth may increase operating noise.
F101 020
10. Install the gear block assembly.
Install the bearing block and gear assembly

into the body cavity. Align the assembly marks to
ensure that the gear block assembly is installed with
the same orientation as before disassembly.
F101 022
11. Clean the mating surfaces.
Remove any excess lubrication and grease

from the mating surfaces of the pump body. Ensure
that these surfaces are dry and free of contamination
before moving on to the next step.
F101 023
22

12. Install the dowel pins.
Install four 5 mm dowel pins into the proper

cavities on both sides of the body (refer to the
illustration). Swab the pins with assembly grease or
petroleum jelly to retain them during assembly.
Do not install dowel pins to the rear cover

or flange, as one of them may drop inside the
pump during assembly.
Dowel Pins
F101 024
P101 131
13. Clean the mating surfaces.
Remove any excess lubrication and grease

from the mating surfaces of the front flange and rear
cover. Ensure that these surfaces are dry and free of
contamination before moving on to the next step.
Ensure the pressure seals are seated properly after

this operation.
F101 025
23

14. Install Rear Cover.
Mount the cover on the body. Ensure the

arrow on the back is oriented properly. The arrow
should be:
• In the same direction as the flow if the unit is

a pump. Inlet Inlet For
For Uni-
• Against the direction of the flow if the unit is a Pump Directional
unidirectional motor. Motor
• If the unit is a bidirectional motor the arrow

does not appear on the cover.
Ensure that all the pressure seals stay in place during

Pump Flow Arrow
this operation. F101 026
15. Prepare pump for front flange assembly.

Place the pump with the rear cover downwards.
Ensure that the assembly marks on the bearing

block / body are properly aligned.
F101 027
16. Install the front flange.
Install a protective sleeve over the shaft.

The sleeve is used to protect the shaft seal from
damage by the shaft splines / keyway during front
flange assembly.
Install the flange onto the body, then remove the

protective sleeve.
Ensure that the seals remain seated in their grooves

during this operation.
F101 028
24

17. Torque sequence. (all except 03 type)
Note: When assembling units with 01 flange

1 3 and short coupled tandems, wash the capscrews
and apply Loctite® 242 or equivalent thread lock
compound to the threads before assembly.
Install capscrews. While observing the

torque sequence shown, pre tighten the
capscrews. Then, using a torque wrench, tighten
them to the proper torque.
Torque 44-54 Nm (32-40 lbf•ft).

4 2
F101 029
18. Install socket head capscrews.

(03 flange and first stage of multiple)
Using a 4 mm internal hex wrench, install the

socket head capscrews to the front flange and rear
cover.
Torque 2.5-3.4 Nm (22-30 lbf•in).
If used, install new o-ring to flange pilot.
Socket Screws
F101 030
Test Relief Valve 19. Testing

After pump has been disassembled and reas-
sembled, it is suggested that the pump be run in
and tested on an appropriate test stand. This is
Outlet Pressure
done to verify the volumetric efficiency and the
Filter integrity of the unit.
Test Pump Test specifications and procedure are given in

Flow Meter section 11.3.
Inlet Pressure
Prime Mover
Temperature
Cooler
Reservoir Reservoir
P101 132
25

20. Prepare the unit for shipment or storage.
Clean the exterior of the pump and install the following:
• Port Plugs
• Key (CI and CO shafts)
• Shaft protective cap (CI and CO shafts)
• Nut and washer (CO shaft)
Port Plug
F101 031
26

7. Multi Stage Pumps

7.1 General
P101 133
7.1.1 Construction
Multiple stage pumps may be purchased directly Socket head capscrews retain the front flange and
from Sauer Danfoss, or individual stages can be rear cover of each stage. The assembly is held
purchased and assembled. Single pumps can also together by hex nuts and studs extending from the
be converted to multiple stages by replacing the rear cover of the final stage to the front flange of the
drive gear (shaft) and front or rear flange. Other first stage. Studs will differ in length depending upon
multiple configurations can be achieved by mixing the displacement combination of all pumps in the
pumps of different groups, however this manual will unit. A table of stud lengths for tandems and a
present information regarding multiple pumps con- formula for calculating stud length of multiples can be
figured strictly from the group 2 product line. found in the appendix, section 11.2.
Intermediate stages are of the FR43 or FR73 type,

and final stage is of the FR03 type. A tang output
shaft and oldham style coupling connect each
stage. Since the coupling requires lubrication
from the pump inlet, the front shaft seal is omitted
on all pumps except the first stage.
27

7.2 First Stage Pump Preparation
Drive Gear Front

Rear Flange (Shaft) Flange
Shaft Seal Shaft
Seal
Socket Head
Capscrew*
Socket Head
Capscrew*
Pressure Seals
* Not used in converted first

stage pumps.
Idler Gear
P101 134
7.2.1 General
The figure above shows a cross section of a typical First stage pumps supplied from the factory are
group 2 first stage pump. A first stage pump can be pre-assembled with two socket head cap screws
purchased directly from the factory or it can be made on the front flange, and two in the rear flange.
from a single stage pump. When a first stage pump is converted from a single
pump, the socket head capscrews are omitted.
The front and rear flanges will then be retained by
the main capscrews (or studs) of the assembled
multiple pump.
7.2.2 Model Code
The model code for ordering a first stage pump is:
SNP2/..yy4x
Where:
‘yy’ is the shaft type (CO/CI/SC/FR)
‘x’ is the flange type
See: Model Code, pages 8 and 9.
28

7.2.3 Converting a Single Stage Pump to a First Stage Pump
To prepare a first stage unit from a single pump, A first stage pump when converted from a single
following components are required: pump, will not require the small socket head
capscrews as shown in the figure. The front flange
• Single pump having the same configuration will be retained by the four main capscrews (or
(flange and porting) as the desired first stage studs) of the multi stage pump.
pump.
• Drive gear (shaft) for the first stage pump.
• Rear flange of the correct rotation.
• Rear shaft seal.
7.2.4 Conversion Procedure
The instructions given here show the unique steps

involved when converting pumps. In addition to
these, follow the assembly and disassembly instruc-
tions in sections 5 and 6.
1. Open the pump, remove the flange, rear cover,

and gear block.
2. Replace the existing drive gear (shaft) with the

appropriate new shaft.
3. Lubricate shaft seal with grease and install into

the seal cavity of the rear flange. Snap ring is not
required to retain the rear shaft seal.
4. Lubricate the pressure seals with grease and

install into the rear flange.
5. Using assembly grease to retain them, install the

dowel pins to the pump body.
6. Install the rear flange. Ensure the rear flange has

the correct direction of rotation.
7. Using a protective sleeve on the shaft, install the

front flange.
The first stage pump is now ready to be assembled

with the other stages.
29

7.3 Intermediate Stage Pump Preparation

Rear Shaft Seal Drive Gear Front Flange
(Shaft)
Coupling
Socket Head
Capscrew*
Socket Head
Capscrew*
* Not used in converted

Pressure Seals intermediate stage
Rear Flange pumps.
P101 135
7.3.1 General
The figure above shows a cross section of a typical Intermediate stage pumps supplied from the fac-
group 2 intermediate stage pump. An intermediate tory are pre-assembled with two socket head cap
stage pump can be purchased directly from the screws on the front flange, and two in the rear
factory, or it can be made from a single stage pump. flange. When an intermediate stage pump is
converted from a single stage pump, the socket
head capscrews are omitted. The front and rear
flanges will then be retained by the main studs of
the assembled multiple pump.
7.3.2 Model Code
The model code for ordering an intermediate stage

pump is: x Porting
Flanged port with threaded holes in "X" patern
SNP2/...FR73....x B (German standard ports), centered on the body
Where: Flanged por t with threaded holes in "+" patern

C (European standard por ts)
‘x’ is the type of porting required as ex- E Threaded SAE o-ring boss por ts
pressed in the table at the right.
See: Model Code, page 8 and 9. F Threaded Gas por t (BSPP)

G (German standard ports), offset from center of body
T101 137E
30

7.3.3 Converting a Single Stage Pump to an Intermediate Stage Pump
To prepare an intermediate stage pump from a single

stage pump, the following components are required:
• SNP2/...FR03 type pump with the desired

porting and rotation.
• Drive gear (shaft) for intermediate stage pump.
• Rear flange of the appropriate rotation.
• Rear shaft seal.

1. Remove the capscrews, rear cover, and drive

gear (shaft).
2. Replace the drive gear (shaft) with the interme-

diate pump drive gear.
3. Lubricate the rear shaft seal with grease and

install it into the seal cavity of the rear flange.
Snap ring is not required to retain the rear
shaft seal.

install into the rear flange.

6. Install the rear flange onto the pump body.
The intermediate stage pump is now ready to be

assembled with the other stages.
31

7.4 Final Stage Pump Preparation

Drive Gear
Rear Cover (Shaft) Front Flange
Socket Head Coupling

Capscrew*
Socket Head
Capscrew*
Pressure Seals
* Not used on converted

final stage pumps.
P101 136
7.4.1 General
The figure above shows a cross section of a typical Final stage pumps supplied from the factory are
FR03 type pump. Even though this pump is a standard pre-assembled with two socket head cap screws
single stage pump, it is commonly used as a final stage on the front flange, and two in the rear cover.
pump. This pump can be purchased directly from the When an intermediate stage pump is converted
factory, or it can be made from a single stage pump. from a single stage pump, the socket head
capscrews are omitted. The front and rear flanges
will then be retained by the main studs of the
assembled multiple pump.
7.4.2 Model Code
The model code for ordering a final stage pump is:

x Porting
SNP2/...FR03....x
B (German standard ports), centered on the body
Where:
Flanged por t with threaded holes in "+" patern
‘x’ is the type of porting required as ex- C (European standard por ts)
pressed in the table at the right.
E Threaded SAE o-ring boss por ts
See: Model Code, pages 8 and 9.
F Threaded Gas por t (BSPP)

G (German standard ports), offset from center of body
T101 137E
32

7.4.3 Converting to a Rear Stage Pump
To prepare a final stage pump from a single stage

pump, the following components are required:
• SNP2 single stage pump with the desired

porting and rotation.
• Final stage drive gear (shaft).
• 03 or 73 type front flange of the appropriate

rotation.

1. Remove the front flange and drive gear (shaft)
from the pump.
2. Replace the drive gear (shaft) with a final

stage drive gear.

install them to the front flange. No shaft seal is
required on the final stage pump.

5. Install the front flange onto the pump. Ensure

that the flange has the appropriate direction of
rotation.
The final stage pump is now ready to be assembled

with the other stages.
33

7.5 Assembly of Multi-Stage Pumps

1. Install the coupling.
Place the first stage pump on the work bench, so that
the rear flange is in the upward position.
If necessary, remove burrs on the flange. Blow the

surface and cavity of the flange with compressed air
to remove any debris before assembly.
Fit the coupling onto the rear tang of the shaft.

2. Install studs and torque.
Clamp the first stage of the pump in a vice on the front
flange side. Install the studs.
Coupling
Torque to 5-10 Nm (4-7 lbf•ft).
F101 030
Stud length tables and guidelines are found in the
appendix, sections 11.1 and 11.2.
3. Assemble the stages.
If necessary, remove burrs from the front flange of
the second stage pump, then clean with com-
pressed air.
Lubricate the pilot and o-ring with grease.
Mount the second stage pump onto the rear pad of

the first stage. Align the tang of the shaft with the
coupling. The two tangs must be rotated 90° from
each other. The coupling will not engage the shaft
O-Ring if it is not properly aligned. Press units together until
the pilot is fully engaged.
F101 033 Repeat this operation for every pump stage.
Capscrews shown in place of hex nuts and studs

4. Install and torque hex nuts.
Install the hex nuts.
1 3
Torque to 50-60 Nm (37-44 lbf•ft).
Use the torque sequence shown at the left.
Test and prepare the pump for shipment or storage

as shown in steps 19 and 20 on pages 25 and 26.
4 2
F101 029
34

7.6 Change of Rotation
7.6.1 General 7.6.2 Determining the Direction of Rotation

The SNP2 pumps are designed with the pressure The direction of rotation of a given flange can be
seals located in grooves on the rear cover and front determined by referencing its part number in the
flange. Therefore the front flange must be replaced appropriate parts list. Direction of rotation can also
whenever a changing rotation. The front flange of a be determined by the appearance of the flange.
pump is ‘oriented’ for a particular direction of rotation. Compare to the photographs shown on this page.
The seal groove encloses the high pressure area or
Rear covers, except in multiple configurations, may be outlet of the pump (inlet of unidirectional motors).
rotated 180° to be used in either direction of rotation. When observed from the inside (looking at the sealed
surface), the high pressure area will be on the left
side in clockwise pumps, and on the right side for
anti-clockwise rotating pumps.
Clockwise Rotation Anti-Clockwise Rotation
Front Front
Inlet Inlet
F101 035 F101 037
Rear Rear
Inlet Inlet
F101 036 F101 038
35

7.6.3 Model code 7.6.4 Conversion procedure

Rotation is expressed in the model code as follows: To change rotation of a pump, the following compo-
SNP2/...x.... nents are required:
Where ‘x’ is: • A front flange of the appropriate direction of

rotation.
D = Clockwise, right hand rotation.
S = Anti-clockwise, left hand rotation. • A rear cover if converting a multistage pump.

1. Remove front flange.
Remove the capscrews and place the pump

on the work bench with the rear cover down. Remove
the front flange.
Mark the position of the front bearing block

for reassembly.
F101 039
2. Remove bearing block and drive gear / shaft.

Remove the front bearing block.
Mark the relative position of the gear teeth

for reassembly.
Remove the drive gear / shaft.
F101 040
36

2. Remove idler gear.

Remove the idler gear from the body cavity, leaving
the rear bearing block in place.
F101 041
3. Move idler gear.

Install the idler gear into the opposite position in the
bearing block.
F101 042
4. Reinstall the drive gear / shaft.

Reinstall the drive gear / shaft. Align the gear teeth
to the assembly marks.
F101 040
37

5. Install front bearing block.
Install the front bearing block into the body cavity.
Align the assembly marks.
F101 043
6. Install the new front flange.

Old Flange (CW) New Flange (CCW) Install the seals and assemble the new front flange
onto the pump body.
F101 044
Note: Follow step 7 only if converting the first or

an intermediate stage of a multiple pump.
If converting a single pump or the final
stage of a multiple pump skip step 7.
7. Multiple pumps only, change the rear flange.

Turn the pump over and remove the rear flange.
Install new pressure seals and shaft seal to the

new rear flange.
Install the new rear flange to the pump body.
38

8. SKP2 Pumps
8.1 General Information
SKP2 Pumps are designed to accommodate an The differences between SKP2 and SNP2 pumps
11 tooth SAE splined shaft for higher torque are described in this section.
applications.
Front cover for clockwise and

counter clockwise rotation
Shaft Seal
Snap Ring
Backup Ring
F101 045
Rubber Pressure Seal

Rear cover orientation symmetrical
O-Ring
39

8.1.1 Bearing Block For SKP2

High Pressure Side
In SKP2 pumps, the pressure seals are located on
the bearing blocks as shown.
Teflon Rubber Pressure

Backup Ring Seal
Low Pressure Side

F101 046
8.1.2 Drive Gear Shaft Differences

SNP2 Drive Gear
The shaft on the drive gear for the SKP2 is larger than
the shaft on the drive gear for the SNP2. The journal
diameters of the SKP2 shaft are 20 mm [.787 in],
while the shaft of the SNP2 is 18 mm [.708 in].
SKP2 Drive Gear

F101 047
SKP2 Front Cover SNP2 Front Cover

8.1.3 Front and Rear Flange Differences
In the SKP2, the front and rear cover can be utilized
for both clockwise and counter clockwise rotation.
With the SKP2, it is not necessary to change the front
and rear cover when changing the direction of rota-
tion. With the SNP2, you must change the front cover
and rotate the rear cover when changing the direc-
tion of rotation.
SKP2 Rear Cover SNP2 Rear Cover

F101 048
40

8.1.4 Bearing Block Differences

SKP2 Bearing Blocks SNP2 Bearing Blocks
In the SKP2, the pressure seal and backup ring are
mounted in grooves on the bearing blocks, while in High Pressure
the SNP2, the pressure seal and backup ring are
mounted in grooves on the front flange and rear
cover. In the SKP2, the bearing blocks must be
installed with the correct orientation to the high and
low pressure sides. The bearing blocks for the SNP2
are symmetrical with respect to the high and low
pressure sides.
Low Pressure
F101 049
41

8.2 Changing the Rotation of SKP2

There is no additional hardware required to change
the rotation on an SKP2 pump.

1. Remove drive gear and front bearing block.
Remove the capscrews and place the pump on the
work bench with the rear cover down. Remove the
front flange.
Remove the drive gear / shaft and front bearing block

only. Hold a finger on the idler gear hole to keep it in
place while removing the drive gear / shaft and
bearing block.
F101 050
Mark the position of the front bearing block
relative to the body. Also, mark the position of the
mating gear teeth relative to each other.
2. Remove idler gear.

Remove the idler gear from the body, leaving the rear
bearing block in place.
F101 051
3. Install idler gear into the opposite position.

The idler gear, that was just removed, must now be
installed into the other side of the body cavity.
F101 052
42

4. Install the drive gear / shaft.

Reinstall the drive gear into the free side of the body
cavity.
Align the assembly marks on the gear teeth.
F101 053
5. Install the front bearing block.

Install the front bearing block into the body.
Align the assembly marks on the bearing

block and body..
F101 054
6. Install the front flange.

Rotate 180° and re-Install the front flange.
F101 055
43

9. Product Options
9.1 Rear Cover with Integral Priority Flow Divider Valve
9.1.1 General Information
Group 2 pumps are offered with an optional priority
flow divider valve integrated into the rear cover. Flow
and pressure settings are made at the factory and
are not adjustable.
When necessary, flow divider covers may be disas-

sembled for cleaning and inspection only.
9.1.2 Disassembly and Reassembly

1. Remove the capscrews and rear cover.
Remove the capscrews holding the pump together.
Remove the rear cover and set aside.
2. Remove the flow control spool assembly.
Remove the caps at each end of the spool. Remove
the dowty washer from the spring end cad. Remove
the spool and spring.
F101 056
3. Remove the pilot relief valve.

Remove the cap, dowty washer, shims, spring, and
plunger from the cavity.
Caution: Shims are required to set the relief

pressure. Retain all shims for reassembly.
F101 057
4. Inspect flow control orifice.

Check the flow control orifice (located in the prior-
ity flow port) for debris or obstruction. Clean as
necessary.
Caution: The flow control orifice is press fit

at the factory. Do not attempt to remove it.
5. Inspect, clean, and reassemble.
Inspect components for damage. Clean and remove
any debris from parts and cavities. Reassembly is
the reverse of above.
F101 058
44

9.2 Rear Cover with Integral Relief Valve
9.2.1 General Information

Group 2 pumps are offered with an optional adjust-
able relief valve integrated into the rear cover.
When necessary, the relief valve may be disas-

sembled for cleaning and inspection.
9.2.2 Disassembly and Reassembly

1. Remove the relief valve assembly.
Using a 24 mm hex wrench, remove the relief valve
cartridge from the rear cover, remove the washer,
spring, spring seat, and poppet from the cavity.
2. Inspect, clean, and reassemble.
Inspect the poppet and mating seat in the housing
for damage. Clean and remove any debris from
parts and cavity. Reassemble in reverse order of
disassembly.
Torque relief valve cartridge to 47 Nm

(35 lbf • ft).
3. Check and reset relief valve pressure.
Using an appropriate test stand, check and if F101 059
necessary, reset the relief valve to the proper
pressure setting.
The adjustable relief has 4 setting ranges. The

outside of the valve housing will be stamped with a
number as follows:
• “0” has a range from 3-25 bar (43.5-363 psi).
• “1” has a range from 26-40 bar (377-580 psi).
Turn the adjustment screw clockwise to increase

pressure, anti-clockwise to reduce.
Refer to the appendix, section 11.3, for information

on testing pumps.
45

10. Trouble Shooting

10.1 Low or No Flow From Gear Pump
Item Description Action
1. Check oil level in reservoir. Insufficient oil to supply gear pump. Fill reservoir to proper level.
2. Check input spline condition. Input shaft broken or stripped. Repair or replace gear pump.
3. Check pressure at pump inlet. Clogged suction filter or inlet Replace filter or clean suction
Recommended inlet pressure: screen. screen.
0.8 to 3.0 bar absolute. 0.6
Minimum at cold start.
4. Check condition of gear faces Scored bearing block and gear Repair or replace gear pump.
and bearing blocks. faces will reduce pump efficiency.
5. Check bushings. Overpressure of gear pump will Repair or replace gear pump.
cause idler gear bushing to fail.
10.2 Excessive Noise
1. Check oil level in reservoir. Excessive air will cause cavitation Fill reservoir to proper level
sound.
2. Check inlet line for leaks. Excessive air will cause cavitation Repair inlet line.
sound.
3. Check pressure at pump inlet. Lower than normal inlet pressure Return inlet pressure to recom-
causes excessive pump noise. mended levels.
Recommended inlet pressure:
0.8 to 3.0 bar absolute. 0.6
Minimum at cold start.
10.3 External Leakage
1. Check for pinched o-rings or Pinched seal will allow leakage. Replace pinched seal.
backup ring seal.
2. Check pressure seals. Damage to pressure seals is Inspect condition of bearing blocks.
typically caused by reduced If they are found to be worn, repair
“stack-up” in the pump assem- or replace the pump.
bly. This may be due to under-
torqued assembly fasteners, or If bearing blocks are not worn,
more commonly is attributed to replace pressure seals and re-
excessive wear on the bearing torque pump assembly fasteners.
blocks. Reduced “stack-up” will
affect seal efficiency possibly
to the point of seal extrusion.
46

Notes
47

11. Appendix
11.1 Stud Specifications
Studs used to assemble multiple pumps must com- mm [in]
ply with the following specifications. A ø 0.220 [0.009] A
• Type Stud
[0.063]
1.6
M10 -6g
M10 -6g
• Thread Dimension ISO M10
• Design Standard DIN 931 1.6 1.6
[0.063]
[0.063]
• Strength Class (minimum) 10.9

0 0
ø 10-0.220 [0.394 -0.009 ] 1 [0.039] x 45°
• Surface Treatment Blued 1 [0.039]x45°
20-23 [.0788-.0906]
15 ±0.55
[0.591±0.021]
MSL
P101 137
MSL = Maximum Stud Length (see section 11.2 below)
11.2 Stud Length For Multi-Stage Pumps

11.2.1 Tandem Pumps
The table contains a list of stud lengths for any

tandem combination of SNP2 pumps.
Front Rear Displacement (type)

Disp. 4 6 8 11 14 17 19 22 25
4 180 183.5 187.5 191.5 197.5 201.5 205.5 211.5 215.5
6 183.5 187 191 195 201 205 209 215 219
8 187.5 191 195 199 205 209 213 219 223
11 191.5 195 199 203 209 213 217 223 227
14 197.5 201 205 209 215 219 223 229 233
17 201.5 205 209 213 219 223 227 233 237
19 205.5 209 213 217 223 227 231 237 241
22 211.5 215 219 223 229 233 237 243 247
25 215.5 219 223 227 233 237 241 247 251
T101 139E
The stud length tolerance is +0 to -0.5 mm

[+0 to -0.02 in].
Note: The data given in the tables does not include

SHP2 pumps which are longer than SNP2.
See section 11.2.2.
48

11.2.2 Multi-Stage Pumps (General Rule)

The following is a general rule that explains how to Given as a formula:
calculate the stud length for any multiple combina-
tion of the SNP2 / SEP2 pump series. This calcula- MSL = TBL + TRFL + TFFL + RCL + 14mm [0.55 in]
tion is essentially the combined length of all compo-
Where:
nents in the stack, plus 14mm [0.55 in] to account for
minimum thread engagement. MSL = Maximum Stud Length
TBL = Total Length of all Bodies
Stud length calculated in this manner has a tolerance
of +0 to -0.5mm [+0 -0.02 in]. TRFL = Total Length of all intermediate Rear Flanges
TFFL = Total Length of all intermediate Front Flanges
RCL = Length of Rear Cover
(from the sealing surface to the nut’s spotface)
11.2.3 Component Lengths
Typical values for component lengths are found in

the following tables. If the components you are using
are not included, measure.
Length
BODY (SNP/SEP/SKP 2)
mm [in]
SNP 2 / 4 50.5 [1.988]
SNP 2 / 6 54 [2.126]
SNP 2 / 8 58 [2.283]
SNP 2 / 11 62 [2.441]
SNP 2 / 14 68 [2.677]
SNP 2 / 17 72 [2.835]
F101 060
SNP 2 / 19 76 [2.992]
SNP 2 / 22 82 [3.228]
SNP 2 / 25 86 [3.386]
T101 140E
Length
Item
mm [in]
Intermediate rear flang 19 [0.748]
Intermediate front flange 18 [0.709]

Cover
13 [0.512]
(mounting face to nut spotface)
T101 141E
49

11.3 Testing the Pumps and Motors
11.3.1 General Test Relief Valve
After assembling a pump, it should be tested to verify

that volumetric efficiency is sufficient to insure satis-
factory performance.
Outlet Filter
Motors can be tested as pumps. Bi-directional mo- Pressure Prime Mover
tors should be tested in both directions of rotation.
Test Pump
Flow rate at drain of motor should be monitored
Flow Meter
during test.
Inlet
Pressure
In order to test a pump, it must be operated on an
appropriate test apparatus. Schematic diagram for a
Temperature Cooler
typical test apparatus is shown in the figure at the
right. Ensure that the test apparatus has sufficient
power available to meet the demand of the pump
under test (see specifications, page 10).
Reservoir Reservoir
The output flow should meet or exceed the specified P101 132
value given in the table. If the pump does not pass
test, it is necessary to disassemble the pump and find
the cause. Refer to Section 10, Troubleshooting,
(page 46) for more information. It may be necessary
to check some dimensions and replace either incor-
rect, damaged, or worn parts.
11.3.2 Test Procedure 11.3.3 Tables
Set up the pump on the test apparatus with suit-

able shaft couplings and port adaptors. Use ap- Pump Flow Limits Table
propriate fluid per ISO VG468. Start the prime
Minimum Output Flow
mover and run the pump until the oil temperature Type
is 40° to 45°C [104° to 113°F] as measured in the l/min [US gal/min]
inlet line. 4 5.6 [1.48]
Set up the following test parameters: 6 8.6 [2.27]
8 12.1 [3.20]
• Pump Speed 1500 rpm
11 15.5 [4.09]
• Inlet Vacuum 0.15 bar 14 20.7 [5.47]
[2.175 psi]
17 24.3 [6.42]
• Outlet Pressure See Table 19 27.8 [7.34]
Run the pump for one minute at the pressure noted 22 33.0 [8.72]
in the table and check the output flow at the flow
25 36.5 [9.64]
meter. For motors, check the flow at the drain as well.
T101 142E
If the pump is in good condition, the measured flow
rates will meet limits given in the flow limits table.
50

11.3.3 Tables (cont.)
Motor Flow Limits Table

Minimum Output Flow Maximum Drain Flow
Type
l/min [US gal/min] l/min [US gal/min]
6* 8.6 [2.27] 0.30 [0.079]
8 12.0 [3.17] 0.30 [0.079]
11 15.5 [4.09] 0.35 [0.092]
14 20.6 [5.44] 0.40 [0.105]
17 24.1 [6.37] 0.40 [0.105]
19 27.6 [7.29] 0.40 [0.105]
22 33.0 [8.72] 0.40 [0.105]
25 36.5 [9.64] 0.40 [0.105]
T101 143E
Test Pressure Table (Pumps)

SEP 2 SNP 2 SKP 2 SHP 2
Type
bar [psi] bar [psi] bar [psi] bar [psi]
4 225 [3265] 250 [3625] 250 [3625] N.A. N.A.
6 225 [3265] 250 [3625] 250 [3625] N.A. N.A.
8 225 [3265] 250 [3625] 250 [3625] N.A. N.A.
11 225 [3265] 250 [3625] 250 [3625] N.A. N.A.
14 180 [2611] 250 [3625] 250 [3625] N.A. N.A.
17 180 [2611] 250 [3625] 250 [3625] N.A. N.A.
19 N.A. N.A. 210 [3045] 240 [3481] 240 [3481]
22 N.A. N.A. 180 [2610] 210 [3045] 210 [3045]
25 N.A. N.A. 160 [2320] 190 [2756] 190 [2756]

T101 144E
Test Pressure Table (Motors)

SEM 2 SNM 2 SNU 2 SHM 2
Type
bar [psi] bar [psi] bar [psi] bar [psi]
6* 210 [3045] 230 [3335] - - - -
8 210 [3045] 230 [3335] 250 [3626] - -
11 210 [3045] 230 [3335] 250 [3626] - -
14 210 [3045] 230 [3335] 250 [3626] - -
17 210 [3045] 220 [3190] 230 [3335] - -
19 180 [2610] 210 [3045] 210 [3045] 240 [3481]
22 160 [2320] 180 [2610] 180 [2610] 210 [3045]
25 140 [2030] 160 [2320] 160 [2320] 190 [2756] T101 145E
* Inapplication
addition to the prescribed test procedure, it is recommended that the 6cc motor be tested also as a motor. This can be done in the
by providing flow to the motor inlet to with no torque on the shaft at start-up. Motor will be considered to have passed this
test if it performs satisfactorily under the application’s normal load.
51

11.4 Tools mm [in]

This section contains drawings useful in fabricating
any specialized tools required to service group 2
gear pumps and motors.
11.4.1 Shaft Seal Installation Tool
70 [2.756]
5 [0.197]
15 50 [1.969 ]
[0.590 ]
3 [0.118]
12 [0.472]
°
45
x
0]
02
.
[0
5
0.
1 [0.039] x 45°
R
1.
5
[0
.0
5
9]
[0.787]
[0.787]
[1.575]
[1.118]
[0.669]
Ø28.4
Ø20
Ø20
Ø40
Ø17
2 [0.
2 [0.079 ] 79]
2 [0.0
079]
15 °
P101 138
52

11.4.2 Shaft Seal Protective Sleeves mm [in]
Ø17.7 +0.05
-0 Ø17.7 +0.05
-0
[0.697 +0.002
-0 ] [0.697 +0.002
-0 ]
Ø17.4 Ø17.4
[0.685 ] R0.1[.004] [0.685 ] R0.1[.004]
1:8 Ø13 Ø13
1:5
[0.512 ] [0.512 ]
15 [0.591] 19.5 [0.768]

22 [0.866 ]
35 [1.378 ]
35 [1.378 ]
15 [0.591 ]
60 [2.362 ]
60 [2.362]
25.5 [1.004]
08 08
23 [0.906 ]
R1[0.039]
R1[0.039]
10 ° 10 °
Ø3 [0.118 ] Ø3 [0.118 ]
CO01 Shaft CO02, 04 Shaft
Ø17.7 +0.05
-0 Ø17.7 +0.05
-0 Ø17.7 +0.05
-0
[0.697 +0.002
-0 ] [0.697 +0.002
-0 ] [0.697 +0.002
-0 ]
R0.5[0.020] R0.5[0.020] R0.5[0.020]
Ø16.5 +0.05
-0.03 Ø16.5 +0.05
-0.03 Ø15.456 +0.05
-0.03
-0.001]
[0.650 +0.002 R0.1[.004] -0.001 ]
[0.650 +0.002 R0.1[.004] -0.001 ]
[0.609 +0.002 R0.1[.004]
16 [0.630]
21 [0.827]
27 [1.063]
35 [1.378 ]
35 [1.378 ]
35 [1.378 ]
60 [2.362]
60 [2.362]
60 [2.362]
44 [1.732]
39 [1.535]
33 [1.299]
08 08 08
R1[0.039]
R1[0.039]
R1[0.039]
10 ° 10 ° 10 °
Ø3 [0.118 ] Ø3 [0.118 ] Ø3 [0.118 ]

SC01 Shaft SC02 Shaft SC06 Shaft
Ø19 +0.05
-0 Ø17.7 +0.05
-0 Ø17.7 +0.05
-0
[0.749 +0.002
-0 ] [0.697 +0.002
-0 ] [0.697 +0.002
-0 ]
R0.5[0.020] R0.7[0.028] R0.7[0.028]
Ø17.8 +0.05
-0.03 Ø15 Ø15.875 +0.05
-0.03
-0.001]
[0.701 +0.002 R0.1[.004] [0.609] R0.2[.008] -0.001 ]
[0.625 +0.002 R0.2[.008]
[0.394]
10
27 [1.063]
33 [1.299]
35 [1.378 ]
35 [1.378 ]
35 [1.378 ]
60 [2.362]
60 [2.362]
60 [2.362]
50 [1.969]
33 [1.299]
27 [1.063]
08 08 08
R1[0.039]
R1[0.039]
R1[0.039]
10 ° 10 ° 10 °
FR03 Shaft Ø3 [0.118 ] CI01 Shaft Ø3 [0.118 ] CI06 Shaft Ø3 [0.118 ] P101 139E
53

11.5 Shaft Dimensions mm [in]
This section contains dimensions and specifications

for standard shafts.
-0.25 [ .374 -.010 ]

11.5.1 Shafts Used with 01 Flange
+.006
40.5 [1.596]
17 [.670] -.001]
4 +0-0.030 [ .158 +0 CO01 Tapered Shaft
9.5 +0.15
16.05 [.632] max
Type: 1:8 Taper Shaft
5 [.020]
-.003 ]
[1.438 +.001
Key Data: 4 x 6.5 ISO 3912

Ø 36.5 -0.025
-0.064
Section : A-A
Technical Specifications:
A
Nut Torque: 35-50 Nm
[26-37 lbf•ft]
Maximum Shaft Torque: 150 Nm

15.7 ±0.50 [.619 ±.020]
[111 lbf•ft]
M12x1.25-6g
X
Ø 16.662 [.656]
1:8
P101 140E
36.5 [1.438] CI01 Parallel Shaft
30 [1.182] Type: Parallel

-0.20 [.650 -.008 ]
-..001]
+.004
[.591 +0
6.5 [.256] Key Data: A 4x4x25 UNI 6604
16.5 +0.10
Ø 15 -0.018
4 +0-0.030 [.158 +0
-.001]
+0
B Maximum Shaft Torque: 90 Nm

[66 lbf•ft]
B Section :B-B
16mm [.630] deep
M6 Thread
P101 141E
54

mm [in]
SC01 Splined Shaft

19.5 [.768]
Type: 9 Tooth Spline
10 [.394]
Spline Data: 17 x 14 DIN 5482
6.5 [.256]
Circular Tooth Thickness (sw): 3.206 mm
-.004 ]
[.650 +0
Profile Correction: + 0.6
-0.110
+0
Ø 16.5
[66 lbf•ft]
B17x14 DIN 5482

profile offset +0.6
Spline
P101 142E
55

mm [in]
11.5.2 Shafts Used with 02 Flange
CO02 Taper Shaft

Key Data: 3 x 6.5 ISO 6604

(DIN 6888)

[30-37 lbf•ft]

[103 lbf•ft]
P101 143E
SC02 Splined Shaft

Type: 9 Tooth Spline
Circular Tooth Thickness (s w): 3.206 mm

[96 lbf•ft]
P101 144E
56

mm [in]
11.5.3 Shafts Used with 04 / 05 Flange
40.5 [1.594]
-0.10 [.354 -.004 ]

+.012
19 [.748] Section : A-A
CO04 / CO05 Taper Shaft
19.3 [.760] 3 +0-0.025 [.118 +0-.001 ]
9 +0.30
7.2 [.283]
Key Data: 3 x 6.5 ISO 6604 X
(DIN 6888)
17.46
[.687]
A

[30-37 lbf•ft]
M12x1.25-6g
15.7±0.50 [.618 ±.001 ]
-0.064 [1.969 -.003 ]

A
+.001
[103 lbf•ft]
Ø50 +0.025
1:5 P101 145E
26 [1.024]
SC04 / SC05 Splined Shaft
Type: 9 Tooth Spline 13.5 [.531]
Circular Tooth Thickness (sw): 3.206 mm
[.650 +0-.004 ]

[96 lbf•ft]
-0.110
+0
Ø16.5
spline
B17x14 DIN 5482
profile offset +0.6 P101 146E
57

mm [in]
11.5.4 Shafts Used with 06 Flange (SAE)
Cl06 Parallel Shaft
Type: SAE A parallel Shaft

[59 lbf•ft]
P101 147E
-.005 ]
[ .609 +0
SC06 Splined Shaft

-0.127
Type: SAE 9 Tooth Spline

+0
Ø15.456
Spine Data: 9T 16/32DP

SAE J498b
flat root side fit
Circular Tooth Thickness: 0.127 mm [.005]

Spline Data
SAE J498b
less than standard
9T - 16/32DP SAE class 1 fit
FLAT ROOT SIDE FIT
30° pressure angle
14.288 [0.563] pitch diameter Technical Specifications:
(circular tooth thickness
0.127 [0.005] less than
standard class 1 fit) Maximum Shaft Torque: 75 Nm
[55 lbf•ft]
P101 148E
58

mm [in]
SKP2/...SC06 Splined Shaft 38 [1.496]
Type: SAE 11 Tooth Spline 10.5 [.413]
Spine Data: 11T 16/32DP 12 [.472] 6 [.236]
SAE J498b
-0.127 [ .734-.005 ]
+0
flat root side fit
Circular Tooth Thickness: 0.127 mm [.005 in]
Ø18.631 +0
less than standard
SAE class 1 fit

[111 lbf•ft]
P101 149E
59

11.5.5 FR Tang Shaft mm [in]

The shaft type shown in the drawing is called a “tang”
-.25 [0.283 -.010 ]
7.2 +.25 +.010
shaft. This shaft is used in conjunction with an
“Oldham” style coupling and is normally connected 3.2 +.20
-0 [0.125 +.008
-0 ] 2 [0.079]
to another tang shaft on a P.T.O. (Power Take Off).
This shaft is generally supplied with the 03/43 type

OR 45.69 [1.989] x 2.62 [0.103]
flange, and is used as the front drive for multistage
pumps.
Ø52 +.030
[1.339 +.020
[1.882 +0
Ø47.8 +0
-.076 [2.047 -.003 ]

[0.701]
Ø34 +.5
Ø17.8
Caution: Due to the limited dimensions of
-.020 ]
-.008 ]
-.5
-.20
the tang shaft, and to supply lubricating oil for the
+.001
coupling, the 03/43 pumps are supplied without a
15.7+.50
front shaft seal. A shaft seal must be located on
-.50 [0.618 -.020 ]

the P.T.O.
+.020

[52 lbf•ft]
-0 [0.256 -0 ]
6.5 +.20 -0 [0.106 -0 ]
2.7 +.70
+.008 +.028
12 [.472]
8 +.025
-.083 [0.315 -.003 ]
8 [0.315]
Ø19 [0.748]
Ø30 [1.181]
+.001
P101 150E
11.5.6 Mating Design for FR03 Pumps

The sketch of a P.T.O for the FR03 type pumps is
shown. The axial dimensions and positions of the 6.5 +.10
-0 [0.256 -0 ]
+.004
shaft must be strictly met. They are very important for R0.5 [0.020] Max
8 +.025
correct torque transmission. The P.T.O. must have

-.063 [0.315 -.004 ]
its own shaft seal.

+.001
To withstand the maximum torque capacity, the 2.5 -.5

+0
[0.098 -.020
+0
] 8 [0.315] Min
material of the P.T.O. shaft should be case hardened
steel as per DIN 17210 or UNI 5331-64 at least 20 A
MnCr5 (DIN), or 20 CrNl4 (UNI), or better.

52 +.046
The pump mounting holes must be threaded per

[0.669-0.709]
-0
Ø17-18
ISO M10, minimum full thread depth 20mm [0.787 in].

[2.045 +.002
Capscrews used to attach the pump must be strength

-0 ]
class 10.9. Torque 50-60 Nm [37-44 lbf•ft].

30°
Ø0.010 [0.004] A
0.5-0.6
[0.020-0.024]
P101 151E
60

11.6 Flange Types
SNP 2/. . . CI 01 SNP 2/. . . SC 04

SEP 2/. . . CI 01
SNP 2/. . . CO 01
SEP 2/. . . CO 01 SNP 2/. . . CO 05
SHP 2/. . . CO 01
SNP 2/. . . SC 01 SNP 2/. . . SC 05

SEP 2/. . . SC 01
SNP 2/. . . CO 02 SNP 2/. . . CI 06

SHP 2/. . . CO 02
SNP 2/. . . SC 02 SNP 2/. . . SC 06
SNP 2/. . . FR 03 SNP 2/. . . CO 09
SNP 2/. . . CO 04
SNP 2/. . . CO 09. . . BBM
F101 061
61

Notes
62

Notes
63

Hydraulic Power Systems
SAUER-Danfoss Hydraulic Power Systems - Market Leaders Worldwide
SAUER-DANFOSS is a world leader in the design SAUER-DANFOSS specializes in integrating a full
and manufacture of Hydraulic Power Systems. Research range of system components to provide vehicle designers
and development resources in both North America and with the most advanced total-design system.
Europe enable SAUER-DANFOSS to offer a wide
range of design solutions utilizing hydraulic power system SAUER-DANFOSS is Your World Source for
technology. Controlled Hydraulic Power Systems.
Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives
Medium Duty Axial Piston Mikrocontrollers and Hydrostatic Transmissions

Pumps and Motors Electrohydraulic Controls Packages
Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts
Worldwide Service Support
SAUER-DANFOSS provides comprehensive worldwide service for

its products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-DANFOSS for the best in WORLDWIDE SERVICE.
http://www.sauer.com
SAUER-DANFOSS COMPANY SAUER-DANFOSS GMBH & CO.

2800 East 13th Street Postfach 2460 • D-24531 Neumünster
Ames, IA 50010 • U.S.A. Krokamp 35 • D-24539 Neumünster • Germany
Phone: (515) 239-6000 • Fax: (515) 239-6618 Phone: (04321) 871-0 • Fax: (04321) 871 122
SM-GP2-E • 06/99 • 300168
BLN-10168 • May 1999

1
LP8500 ASSEMBLY and DISASSSEMBLY OF THE ECCENTRIC SHAFT
1-DISASSEMBLY
1.1-Remove the vibration motor (item 15), coupling (item 14) and pins (item 9).
1.2-Remove the end cover (item 3).
1.3-Remove the snap ring (item 5).
1.4-Place the housing (item 2) in a vertical position with the shaft end cover (item 11) to
the top.
1.5-Remove the shaft end cover (item 11)
1.6-Lift the eccentric shaft (item 8)
1.7-Remove the bearings (item 6) from the housing and shaft end cover.
2-ASSEMBLY
2.1-Properly clean all parts to be used.
2.2-Try the two bearings (item 6) on the two end journals of the eccentric shaft (item 8).
The fit between the bearings and eccentric shaft must be a snug slide fit.
If necessary polish the eccentric shaft journals to have that type of fit.
Match the bearings to the journals and mark them.
2.3-Place the housing (item 2) in a vertical position with the cover end to the top.
Install the nilos ring (item 7) inside the housing.
2.4-Using a press install the bearing in the housing.

Note: Push the bearing only through the outer race.
2.5-Pack bearing with grease
2.6-Press the other bearing into the shaft end cover (item 11)
Note: Push the bearing only through the outer race.
2.7-Pack the bearing with grease.
2.8-Place the housing (item 2) in a vertical position.

2
LP8500 Eccentric shaft
2.9-Slide the eccentric shaft (item 8) into the inner race of the bearing.
2.10-Install the shaft end cover (item 11) sliding the bearing onto the eccentric shaft
journal.
Apply Loctite 242 and torque the mounting screws (item 12) to 59 lb.ft
(80 N.m).
2.11-Install coupling (item 14) with its key into the motor shaft. Apply Loctite 242
and torque the nut (item 13) to 37 lb.ft (50 N.m).
2.12-Install pins (item 9) on the eccentric shaft and slide the motor (item 15) and
coupling (item 14) into the housing.
Install the motor mounting screws and washers (items 16 & 17) and torque the
screws to 37 lb.ft (50 N.m).
2.13-Place the housing in a horizontal position and install the snap ring (item 5).
Install the end cover (item 3). Apply Loctite 242 and torque the mounting screws
(item 4) to 59 lb.ft (80 N.m).

ELECTRICAL SYSTEM

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LP8500 Electric Troubleshooting-3
Machine does not go into High Speed.

1-With the speed switch in High Speed, check if you have power to the high speed
solenoid Y9 (X20)
1.1-Power
1.1.1-Replace solenoid Y9
1.2-No power
1.2.1-Move the harness plug to the Manual Operation Mode.
1.2.1.1-With high speed switch in High Speed check if you have power to solenoid Y9.
1.2.1.2-Power. Receiver is faulty.

LP8500 Electric troubleshooting-1
1-Fuse #1 (30 A) blows when the emergency switch is turned on (Twist and pop).
Move plug of wiring harness from remote to manual position.
Pull relay K3 out of its socket.

na
Check continuity between socket termi l
s“87”a
nd“
85”
.
1.1-If continuity is positive:
1.1.1-Di
sconne ctconne ctor“X1”f rom r ece iver.
No continuity-Receiver has short circuit.
1.1.2-Di
sconne ctconne ct
or“ X2”f rom r ece i
ve r
.
No continuity-receiver has short circuit
1.1.3-Disconnect Tilt Switch( B14 d1)f r

om c onne c
tor“
X21”
.
No continuity-Tilt switch has short circuit
1.1.4-Di
sconne ctTi l
tSwi tch( B14 d2)f r
om c onne ct
or“
X23”
.
No continuity-Tilt switch has short circuit.
1.1.5-Pull relay K35 out its socket

No continuity-Relay has short circuit
1.1.6-Pull relay K34 out its socket

No continuity-Relay has short circuit.

1
LP8500 Electric Troubleshooting-2
Engine does not start in remote control mode.
Be sure that the transmitter battery is charged and that there is communication between
the transmitter and receiver.
1-Move the wiring harness plug to the manual mode position.

1.2-Engine starts in Manual
1.3-Move harness plug back to the remote control mode position.
1.3.1-Disconnect wire #22(X 16/1) out of the voltage regulator, from black wire that goes
to X8/4.
1.3.2-Connect 12 Volts to wire #22.
1.3.3-If engine now starts, replace voltage regulator.
1.4-Engine does not start in Manual mode.
1.4.1-Check Fuses #1 and #2.
2-Check if you have power to the fuel shut off solenoid (Y1) (X9/1)
2.1-No power
2.1.1-Check if you have power to the ignition Switch S1, connector X25.
2.1.2-Power. Replace Ignition Switch S1.
2.1.3-No power
2.1.3.1-Che cki fy ouha vepowe rtoK35t e r
mina
l“30”( wire218) .
2.1.3.1.1-No power
2.1.3.1.2-Check operation of K3.
If K3 is not operating, replace it.
2.1.3.2-Che cki fre l
ay“ K35”is being energized.
If K35 is being energized, disconnect tilt switches. If K35 de-energizes, check tilt
tilt switches.
2.1.3.3-Pull K35 from its socket.
If now you have power to the fuel shut off solenoid, replace K35.
2.2-Power
2.2.1-Check Fuel shut off solenoid. (Y1).
Resistance between Y1 terminals should be around 10 Ohms.
3-With engine start switch in the start position, check if you have power to the engine
throttle solenoid (2) (X6/1) (Pull).
3.1-No power
3.1.1-Check if you have power to the engine speed switch S3 (X26)
3.1.2-Power. Replace Speed Switch S3
3.2-Power
3.2.1-Check the engine throttle solenoid (Y2)
3.2.1.1-Resistance between Blue and Black wires should be around 21.9 Ohms
3.2.1.2-Resistance between Red and Blue wires should be around 22.1Ohms
3.2.1.3-Resistance between Red and Black wires should be around 0.9 Ohms.

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LP8500 WORKSHOP MANUAL

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Motors Type Radial Pistons

Control valve Type Solenoid actuated

Relief valve Setting 4060 PSI (28 MPa)

Brake valve Max Pressure 4500 PSI (31 MPa)

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4. Components-Repair work 6. Function tests

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This Workshop Manual covers the latest technical developments according to

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

Use only GENUINE HATZ PARTS for repairs!

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Type 2G30 2G40

Sense of rotation pto-side left

Cooling air required at 3000 rpm m3/min. 10.5

Net weight approx. kg 85 depending on model

Oil capacity approx. ltr 2.5 without oil sump

Injection pressure (static) bar 250+8

Tappet clearance (20 ± 10° C)

Max. perm. inclination in ° Exhaust side Flywheel side

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1 Fuel line 18 Lubricating oil line

* not existing in every engine model

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2.1.1. Fuel tank 2.1.2. Fuel filter

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PFR 2K 60A 493

PFR 2K 60A 493

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Check the maintenance switch as follows:

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2.3.1. Exhaust silencer and

Exhaust Cylinder head

Exhaust Exhaust manifold

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2.4.1. Starter 2.4.2. Alternator

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Preparations: - Inspection / repair:

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Preparations: Chapt. 3.5.2.

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2.5.1. Temperature switch 2.5.2. Oil pressure switch

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2.6.1. Stubshaft 2.6.2. Flexible coupling

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2.7.1. Mounting parts for hydraulic Note:

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

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When fitting the cover „23” ensure that the