Hatz Diesel 1D30 S Workshop Manual
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Hatz Diesel 1D30 S Workshop Manual

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Workshop manual
1 D . .
438 202 01 - Printed in Germany

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Summary of Contents for Hatz Diesel 1D30 S

  • Page 1 Workshop manual 1 D . . 438 202 01 - Printed in Germany...
  • Page 3 Contents Foreword 1. General 2. Additional equipments Engine illustrations A 01.00 Fuel Technical data A 01.10 Fuel tank Type plate data A 01.40 Fuel feed pumps Lubrication oil circuit A 02:00 Combustion air Special tools and A 02.10 Oil bath air filters workshop equipments A 02.11 Dry type air filters Jointing material / Sealing and...
  • Page 4 Contents 3. Basic engine M–Disassembly cross reference scheme M 01.00 Crankcase M 17.00 Flywheel M 01.10 Crankcase, nozzle M 26.00 Cowling / Air duct and bearings M 31.00 Breather system M 01.11 Plugs M 32.00 Speed control M 01.20 Crankshaft-thrustplate M 35.00 Capsule and cam followers 4.
  • Page 5 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, inclu- ding all required data etc., so as to permit a trained mechanic to carry out correct and professional repairs.
  • Page 7 1. General 1D . . / 03.06...
  • Page 8 Engine illustrations Engine 1D30, 1D31, 1D40, 1D41, 1D50, 1D60, 1D80, 1D81, 1D90 S/Z/T/U 1 Cooling air inlet 18 Flywheel 2 Oil pressure switch 19 Engine flange 3 Dry type air cleaner 20 Fuel tank 4 Decompression lever 21 Engine base plate 5 Cooling air outlet 22 Exhaust silencer 6 Extra fuel device...
  • Page 9 Engine illustrations Noise-optimized version Engine A1D35, A1D40, A1D41 S/Z/T/U 1 Air filter 16 Speed control lever 2 Oil pressure switch 17 Oil filling hole and dipstick 3 Injection pump bleeder valve 18 Engine base plate 4 Extra fuel device 19 Oil drain plug, control side 5 Air cowling cover 20 Type plate 6 Exhaust silencer...
  • Page 10 Engine illustrations Fully encapsulated version Engine 1D30C, 1D31C, 1D40C, 1D41C, 1D60C, 1D80C, 1D81C 1 Capsule 12 Flywheel 2 Decompression lever 13 Cooling air outlet 3 Cold start-oil priming device 14 Battery connections and central plug 4 Combustion and cooling air intake for electrical system 5 Oil filter 15 Access to timing cover...
  • Page 11 Engine illustrations Engine 1D90 V/W 1 oil filler cap 11 speed control lever 2 dipstick 12 oil filter 3 type plate 13 fuel filter 4 combustion air intake 14 cooling air outle 5 dry type airfilter 15 decompression levert 6 fuel tank drain plug 16 exhaust silencer 7 cylinder head cover 17 electric starter...

  • Page 12: Technical Data

    Technical data Type 1D30.. 1D40.. A1D35.. 1D31.. A1D40.. Engine models S, Z, T, U, C S, Z, T, U, S, Z, T, U Mode of operation Air-cooled four-stroke diesel engine Combustion method Direct-injection Number of cylinders Bore / stroke 86/65 86/65 86/65 Cubic capacity...
  • Page 13 Technical data Type 1D41.. 1D50.. 1D60.. A1D41.. Engine models S, Z, T, U, C S, Z S, Z, T, U, C Mode of operation Air-cooled four-stroke diesel engine Combustion method Direct-injection Number of cylinders Bore / stroke 90/65 97/70 88/85 Cubic capacity Compression ratio 20.0:1...
  • Page 14 Technical data Type 1D80.. 1D90. 1D81.. Engine models S, Z, T, U, C S, Z, V, W Mode of operation Air-cooled four-stroke diesel engine Combustion method Direct-injection Number of cylinders Bore / stroke 100/85 104/85 Cubic capacity Compression ratio 20.5:1 20.5:1 Direction of rotation 1D .
  • Page 15 Type plate data 1D . . / 03.06...
  • Page 16 EPA / Carb type plate data Engine family Type / Spec./ FDT 4 HZX L.667 V 83 1D81 Z 216B 13.0 Type code Static timing (begin of fuel V = variable speed application delivery) C = constant speed application A = V + C as well Customer specification Displacement (in cm or liters)
  • Page 17 Lubrication oil circuit 1D . . / 03.06...
  • Page 18 Special tools and workshop equipments Engine series 1 D . . (SUPRA) Verwendung Ident-Nr. Bezeichnung bei Typen 30-50 60-90 644 345 90 Clip tool for lead plugs 630 815 00 Allen socket 6 mm lg 1/2" 629 301 00 Clamp for pushrod tube –...
  • Page 19 Special tools and workshop equipments 1D . . / 03.06...
  • Page 20 Special tools and workshop equipments Engine series 1 D . . (SUPRA) Verwendung Ident-Nr. Bezeichnung bei Typen 30-50 60-90 633 013 00 Forcing screw for centrif.-clutch Oil pressure gauge 0... 6 bar 620 926 92 630 094 90 Test nozzle 400 bar / 5800 psi 634 142 00 Honing tool 624 838 92...
  • Page 21 Special tools and workshop equipments S T A R 1D . . / 03.06...
  • Page 22 Jointing material / 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.

  • Page 23: Additional Equipment

    2. Additional equipment 1D . . / 03.06...
  • Page 24 A 01.00 Fuel A 01.10 Fuel tank – Preparations: – Dismantling: – Loosen drain plug 1 and drain off fuel or close off fuel supply pipe 2. – Remove (pull off) fuel hoses 2...3 from fuel filter and fuel tank. –...
  • Page 25 A 01.00 A 01.10 1D . . / 03.06...
  • Page 26 A 01.00 Fuel A 01.40 Fuel feed pumps - 25 - I. Fuel feed pump II. Fuel feed pump drive General: General: When connecting the fuel feed pump take Models Z/U/C care for arrangement of suction and supply Bushing 15 is replaced by the actuating hose.
  • Page 27 A 01.00 A 01.40 1D . . / 03.06...
  • Page 28 A 02.00 Combustion air A 02.10 Oil bath air filters – General: Assembly: The oil bath air filter is fitted by means of an – Assemble in reverse sequence 9...1. intermediate flange which adapts from the Ensure the correct amount of gaskets triangle-type flange at cylinder head to the are used and parts seal properly to twin-screw flange of oil bath air filter.
  • Page 29 A 02.00 A 02.10 1D . . / 03.06...
  • Page 30 A 02.00 Combustion air A 02.11 Dry type air filters – Version A 02.11.1 Version A 02.11.2 Fixation of filter element and cover by flat Fixation of filter element separately by washers and Hex.-nuts. retaining plate, flat washers and Hex.-nuts. Preparations: –...
  • Page 31 A 02.00 A 02.11 A 02.11.1 23 Nm 17 lb ft 76.5 A 02.11.2 23 Nm 7 8 9 17 lb ft 1D30 - 1D40 67.5 mm 1D60 - 1D80 64.7 mm 1D . . / 03.06...
  • Page 32 A 02.00 Combustion air A 02.11 Dry type air filters – Version A 02.11.3 Version A 02.11.4 (A 1 D...) Fixation of filter element by front cover Fixation of filter element separately by retai- assembly. ning plate, flat washers and Hex.-nuts. Preparations: –...
  • Page 33 A 02.00 A 02.11 A 02.11.3 A 02.11.4 8 9 10 64.7 1D . . / 03.06...
  • Page 34 A 02.00 Combustion air A 02.13 Service indicators; vacuum gauges – Preparations: – Assembly: Dismantling: – Assemble in reverse sequence 15...10. – Remove in numerical sequence 1...2. 1 D 60 - 80 - 81 only! – Remove in numerical sequence 3...6. –...
  • Page 35 A 02.00 A02.13 1D . . / 03.06...
  • Page 36 A 02.00 Combustion air A 02.20 Pre-cleaners; cyclons – Version A 02.20.1 Version A 02.20.2 Cyclon fitted at bottom side inlet port. Cyclon fitted to front side inlet port. Front inlet port and through holes plugged. Bottom inlet port closed. Preparations: –...
  • Page 37 A 02.00 A 02.20 A 02.20.1 A 02.20.2 1D . . / 03.06...
  • Page 38 A 03.00 Exhausts A 03.12. Exhaust-silencers, high performance / Protection guard - 2 - Version A 03.12.1 Protection guard Exhaust silencer fitted in connection with General: studs, flat washers and hex.-nuts. The fixation of the guard has been modi- Version A 03.12.2 fied to avoid breaks around the fixation Fixation by Allen screws.
  • Page 39 A 03.00 A 03.12 A 03.12.1 A 03.12.2 23 Nm 17 lb ft A 12.30.1 A 12.30.2 1D . . / 03.06...
  • Page 40 A 04.00 Start mechanical / pneumatic A 04.10 Starting handles without supports – Version A 04.10.1 Standard starting handle: Replaceable at any time by a safety starting handle if required or specified. ATTENTION ! Take care, a worn shaft or broken handle can cause serious injuries.
  • Page 41 A 04.00 A 04.10 A 04.10.1 A 04.10.2 14 13 15 2 1 1D . . / 03.06...
  • Page 42 A 04.00 Start mechanical / pneumatic A 04.10 Starting handles without supports – Version A 04.10.2 Anti-kick-back starting handle, specified as – Check condition of plate spring 11 and type A for 1 D.. S/Z/C engines. leg spring 13. ATTENTION ! –...
  • Page 43 A 04.00 A 04.10 A 04.10.1 A 04.10.2 14 13 15 2 1 1D . . / 03.06...
  • Page 44 A 04.00 Start mechanical / pneumatic A 04.11 Starting handle supports A 04.12 Cranking claws – - 25 - General: General: Version A 04.11.1 Version A 04.12.1 Part without replaceable bushing. Part is bonded into camshaft. Version A 04.11.2 Version A 04.12.2 Part with replaceable bushing.
  • Page 45 A 04.00 A 04.11 A 04.12 A 04.11.1 A 04.11.2 A 04.12.1 A 04.12.2 1D . . / 03.06...
  • Page 46 A 04.00 Start mechanical / pneumatic A 04.30 Rope starts – General: Inspection / repair: Recoil starters available respectively fitted – Visual inspection. as additional equipment in connections with – Check all parts in question, inclusive engines as follows: driving elements 15 for wear and / or any other damage.
  • Page 47 A 04.00 A 04.30 S / Z 10 9 T / U 10 9 1D . . / 03.06...
  • Page 48 A 04.00 Start mechanical / pneumatic A 04.30 Rope starts – Slip pawl 11 according to engine model over pawl guide. Short end of torsion spring 11 must fit into groove of pawl. – Push down brake disk 9 with brake spring 10 as specified according to engine model onto rope pulley shaft.
  • Page 49 A 04.00 A 04.30 S / Z 10 9 T / U 10 9 1D . . / 03.06...
  • Page 50 A 05.00 Start electrical General: The execution of electrical equipment depends on voltage (12 V or 24 V) as well as the direction of rotation. Different ring gears, starter motors, coils and magnet segments are applied. 1D . . / 03.06...
  • Page 52 A 05.00 Start electrical A 05.20 Starter motors - 17 - General: Starter motors are different in construction as well as voltage and direction of rotation is concerned. It is of utmost importance not to combine parts from different construction or version. Preparations: –...
  • Page 53 A 05.00 A 05.20 1D . . / 03.06...
  • Page 54 A 05.00 Start electrical A 05.40 Alternator / Magnet segments – General: It is recommended to always check the alternator for degree of function before any disassembly. Ref.: Section 4 Preparations: – Remove flywheel (M 17.00). Version A 05.40.1 The magnet segments are located on the flywheel by means of centering/roll pins.
  • Page 55 A 05.00 A 05.40 A 05.40.1 A 05.40.2 2.8 Nm 2.1 lb ft A 05.40.3 1D . . / 03.06...
  • Page 56 A 05.00 Start electrical A 05.41 Alternator / Coils – Version A 05.41.1 Open coils fixed to the crankcase. Fixation and adjustment of air gap is done by spacers. Preparations: – Remove flywheel and housing. Dismantling: – Disconnect electrical system. –...
  • Page 57 A 05.00 A 05.41 A 05.41.1 3 2 1 min 0.7 mm 1D . . / 03.06...
  • Page 58 A 05.00 Start electrical A 05.41 Alternator / Coils – Version A 05.41.2 (1D 60-80) Coils fitted to support and fixed on bottom side of crankcase. Fixation and adjustment of air gap by moving the complete unit in longitudinal slots. Preparations: –...
  • Page 59 A 05.00 A 05.41 A 05.41.2 min 0.7 mm 1D . . / 03.06...
  • Page 60 A 05.00 Start electrical A 05.41 Alternator / Coils – Version A 05.41.3 Coil encapsulated and fitted to crankcase. – Push coil towards flywheel against Fixation and adjustment of air gap by feeler gauge. moving the coil in longitudinal slots. Ensure flywheel remains in position ! –...
  • Page 61 A 05.00 A 05.41 1D . . / 03.06...
  • Page 62 A 05.00 Start electrical A 05.80 Ring gears – General: Ring gears are different in pitch as well as direction of rotation is concerned. It is of utmost importance not to combine parts with incorrect pitch or rotation. Preparations: – Remove flywheel (M 17.00). Inspection / repair: –...
  • Page 63 A 05.00 A 05.80 S / Z / C °C °F T / U 1D . . / 03.06...
  • Page 64 A 07.00 Lubrication oil A 07.20 Lub.-oil filters, strainers – General: Retro-fit of lub.-oil filter is possible at any time and requires removing of closing cover only. Version A 07.20.1 Version A 07.20.2 Preperations: – Dismantling: – Remove in numerical sequence 1...6. Version A 07.20.2: Spring in filter housing 5 remains.
  • Page 65 A 07.00 A 07.20 A 07.20.1 A 07.20.2 1D . . / 03.06...
  • Page 66 A 07.00 Lubrication oil A 07.30 Oil sumps – General: Additional oil sump may be used to obtain higher oil change intervals. Depending on the oil quantity as required – different oil pans – suctions strainers and adaptors – spacer rings for the oil pan –...
  • Page 67 A 07.00 A 07.30 1D30-31-35-40-41 2.8 l 60 + 60 4.4 l 1D60-80-81 3.2 l 40 + 40 4.5 l 1D . . / 03.06...
  • Page 68 A 09.00 Speed controls A 09.60 Low idle speed stabilization - 5 - 30 - General: Several engine applications require a very – Turn screw I so that lever 3 is facing precise speed governing also in the range of vertical downwards (pin 7 is also in a low idle, for example engines with hydraulic vertical position).
  • Page 69 A 09.00 A 09.60 29.5 30.5 1D . . / 03.06...
  • Page 70 A 11.00 Remote engine controls A 11.10 Stop devices – Version A 11.10.1 Version A 11.10.2 Stop lever S/Z/T/U Stop lever C. Preparations: – Preparations: – Dismantling: Dismantling: – Remove in numerical sequence 1...4. – Remove in numerical sequence 1...10. –...
  • Page 71 A 11.00 A 11.10 A 11.10.1 1 2 3 4 6 A 11.10.2 1 2 3 1D . . / 03.06...
  • Page 72 A 11.00 Remote engine controls A 11.30 Auto. Shut-off device – General: In order to avoid serious engine damage due to insufficient lubrication (e.g. excess tilting of engine), the mechanical shut-off device was developed. Function: If the oil-pressure is too low, the fuel feed and fuel return is shut off by a valve.
  • Page 73 A 11.00 A 11.30 Run: Relief Relief lever lever Feed Return 1D . . / 03.06...
  • Page 74 A 15.00 Housings - flanges - adaptors A 15.20 Adaptor housings – Preparations: – Remove starter motor if so fitted. Dismantling: – Remove in numerical sequence 1...7 depending on kind of application. Parting sheet 9 may remain. NOTE: Removal of parting sheet requires dismant- ling of flywheel 8.
  • Page 75 A 15.00 A 15.20 5 4 6 5 4 1D . . / 03.06...
  • Page 77 3. Basic engine 1D . . / 03.06...
  • Page 79 M - Basic engine M-Disassembly cross reference scheme 1D . . / 03.06...
  • Page 80 M 01.00 Crankcase M 01.10 Crankcase, nozzle and bearings - 9 - 13 Preparations: Assembly: Ref.: M-Disassembly cross reference – Apply locking agent E to bearing 1 and scheme. press firmly in place. For assembly use tool - 9 - Oil spray nozzle Ensure lubrication passages align.
  • Page 81 M 01.00 M 01.10 1D . . / 03.06...
  • Page 82 M 01.00 Crankcase M 01.11 Plugs For versions without add. counter balance the bores for the balancer shafts are closed with plugs to obtain full oil pressure. Variant I Variant II up to series no.: from series no. on: 1 D 30.15 A 1 D 35.13 1 D 30.16 1 D 40.17...
  • Page 83 M 01.00 M 01.11 Variante I Variante II 1D . . / 03.06...
  • Page 84 M 01.00 Crankcase M 01.20 Crankshaft-thrustplate and cam followers - 25 - Cam followers General: Models S/Z/C = anti-clockwise rotation Cam followers symmetrically arranged. Models T/U = clockwise rotation Cam followers asymmetrically arranged. Besides the normal cam follower 3 for the inlet valve a separate cam follower 5 for the exhaust valve is fitted onto the cam fol- lower bracket 6.
  • Page 85 M 01.00 M 01.20 T / U lb ft Pos. 10.9 9 7 6 10.9 10.9 S / Z / C 1.05 mm 1.20 mm 0.9 mm 3.5 mm 0.10 - 0.40 mm 1D90 V/W: 0.05 - 0.10 mm 1D . . / 03.06...
  • Page 86 M 01.00 Crankcase M 01.20 Crankshaft-thrustplate and cam followers - 25 - Crankshaft thrustplate Dismantling: General: Models S/Z/C It is of utmost importance to observe the – Remove in numerical sequence 8...10. specified torque settings in connection Models T/U with the different type tensile strength of –...
  • Page 87 M 01.00 M 01.20 T / U lb ft Pos. 10.9 9 7 6 10.9 10.9 S / Z / C 1.05 mm 1.20 mm 0.9 mm 3.5 mm 0.10 - 0.40 mm 1D90 V/W: 0.05 - 0.10 mm 1D . . / 03.06...
  • Page 88 M 01.00 Crankcase M 01.30 Oil sump and suction sieve – Preparations: Suction sieve: Ref.: M-Disassembly cross reference The strainer housing 6 can be used both scheme. for anti-clockwise and clockwise engines. Only the assembly position is different. Oil sump - At anti-clockwise engines, the stamped L Dismantling: on the base plate and molded L on...
  • Page 89 M 01.00 M 01.30 6(R) 1D30-31-35-40-41-50 1D60-80-81-90 b (mm) S / Z / C T / U 1D . . / 03.06...
  • Page 90 M 01.00 Crankcase M 01.31 Oil sump 1D 50 – General: An aluminium oil sump with add. cowling is fitted into engines 1D50. Furthermore, a folding plate 3 is mounted to the bottom plate. Assembly: – Seal oil sump 1 with sealing medium H. –...
  • Page 91 M 01.00 M 01.31 1D . . / 03.06...
  • Page 92 M 01.00 Crankcase M 01.40 Base plate and oil pressure relief valve – Preparations: Oil pressure relief valve Ref.: M-Disassembly cross reference Dismantling: scheme. – Remove in numerical sequence 6...8. Base plate Inspection / repair: Inspection / repair: – Check relief valve for contamination –...
  • Page 93 M 01.00 M 01.40 1D90V/W: 23 Nm 17 lb ft 1D . . / 03.06...
  • Page 94 M 01.00 Crankcase M 01.50 Cyl.-head screw sealants – General: Sealing caps are used between the crankcase and cyl.-head screws to prevent water and contaminants from entering and causing corrosion. Replace seal caps whenever head bolts are removed. NOTE: Determine the correct position and seal type for the specific engine type.
  • Page 95 M 01.00 M 01.50 S [mm] 1.9-2.2 04219200 2.3-2.6 1D50 04219300 2.7-3.1 04150300 1D30-31-35 40-41-50 1D30-31- 50458400 50392000 35-40-41 1D60-80- 1D60-80- 81-90 50459800 81- 90 04084500 1D . . / 03.06...
  • Page 96 M 02.00 M 02.10 Wear and grinding dimensions 1 D 30 - 31 - 35 - 40 - 41 - 50 Hardness at bearing journals 600 - 680 HV 100 / 55 -60 HRC Rt 1 - 4 R3.3-3.5 R2.4-2.6 R2.4-2.6 Nom.
  • Page 97 M 02.00 M 02.10 13.5 0.008 - 0.01 0.3 0.3 Wear and grinding dimensions 1 D 60 - 80 - 81 - 90 (9.5) Hardness at bearing journals 600 - 680 HV 100 / 55 -60 HRC Rt 1 - 4 R4.0-4.2 R2.8-3.0 R2.8-3.0...
  • Page 98 M 02.00 Crankshaft M 02.20 Crankshaft gearwheel and stubshafts - 12 - 14 - General: Crankshaft gearwheel respectively stub- shaft are shrink fitted. Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove gearwheel 1 respectively stub- shaft 2. For removal use tool - 14 - Inspection / repair: –...
  • Page 99 M 02.00 M 02.20 1D . . / 03.06...
  • Page 100 M 02.00 Crankshaft M 02.30 Crankshaft / Wear sleeve – Preparations: Assembly: Ref.: M-Disassembly cross reference – Assemble in reverse sequence 3...1. scheme. Torque to specification ! Dismantling: Shaft Repair Sleeve – Remove in numerical sequence 1...3. 1 D 60 - 80 - 81 - 90 only! Remove counter weight through cylinder In case the running surface position of the bore.
  • Page 101 M 02.00 M 02.30 lb ft 1D30-31-35-40-41-50 1D60-80-81-90 1D . . / 03.06...
  • Page 102 M 03.00 Bearing flange - 11 - General: Inspection / repair: At the very early stages of serial produc- – Visual inspection. tion certain engines have been equipped Inspection of main bearing should be with a reverse-run safety device fitted into carried out before removal! the bearing flange.
  • Page 103 M 03.00 1D . . / 03.06...
  • Page 104 M 03.00 Bearing flange M 03.10 Bearing flange 1D90V / W Assembly: Dismantling / Wear measurements: – Warm-up crankcase to approx. – see M 03.00 80°C/175°F. – Fixation of thrust ring 2 and shim ring 9 General: into bearing flange with grease (oil The crankshaft axial clearance of engines groove faces towards crankshaft) 1 D 90 V/W is limited at the bearing flange...
  • Page 105 M 03.00 M 03.10 1D . . / 03.06...
  • Page 106 M 04.00 Camshaft and balancer unit M 04.00 Camshaft and balancer unit - 8 - Balancer unit Dismantling: Preparations: – Remove (pull) idler gears 2 from shafts. Ref.: M-Disassambly cross reference – Remove drive gears 3 and balancer scheme. shafts 4. For removal use tool - 8 - Camshaft Dismantling:...
  • Page 107 M 04.00 1D30-31-35-40-41-50 ~ 50mm 1D60-80-81-90 ~ 60mm ˚C ˚F 300 -400 150 -200 1D . . / 03.06...
  • Page 108 M 05.00 Piston with connecting rod M 05.10 Piston and piston rings - 20 - General: Assembly: 1 D 80 - 81 only! – Place piston rings into their correspond- Pistons are different in their combustion ing grooves. bowl cavity. Observe TOP marks on piston rings ! 1 D 40 only! –...
  • Page 109 M 05.00 M 05.10 1 D 40 ε 20.5 22.0 h (mm) 12.0 10.9 max. 0.20 mm max. 0.15 mm max. 0.10 mm 1D80 1D81 1D . . / 03.06...
  • Page 110 M 05.00 Piston with connecting rod M 05.20 Connecting rod – General: – Remove (press) small end bush 5 if nec- Connecting rods can be fitted either way essary. as far as matching-No. and engine speed is concerned. Assembly: The broaching cut as well as an additional –...
  • Page 111 M 05.00 M 05.20 100 mm 0.025 mm lb ft 1D30-31-35-40-41-50 1D60-80-81-90 nom. (mm) max. (mm) 1D30-31-35-40-41-50 52.02 - 52.06 52.15 a Ø 55.00 - 55.02 55.05 b Ø c Ø 28.00 - 28.01 28.03 d Ø 25.03 - 25.04 25.10 nom.
  • Page 112 M 06.00 Cylinder - 21 - 29 - Preparations: Assembly: Ref.: M-Disassembly cross reference – Offset the piston ring gaps by approxi- scheme. mately 120° to each other to avoid ex- cessive blow-by. Dismantling: Piston rings and cylinder have to be –...
  • Page 113 M 06.00 Tab. dim.(max.) 1D30-31 1D41-50-60 1D80 1D81-90 1D35-40 0.45 0.45 0.55 0.60 0.45 0.45 0.55 0.60 0.40 0.40 0.40 0.45 Tab. dim. d 1D30-31-35-40 1D41 1D60 1D80-81 1D90 1D50 nom. 86.00 - .01 90.00 - .01 88.00 - .01 100.00 - .01 104.00 - .01 97.00 - .015 —...
  • Page 114 M 06.00 Cylinder Cylinder 1D50: For 1D50 engines, a press-fit-sleeve is as- sembled to aluminium cooling jacket, hence in case of wear a sleeve replace- ment is possible. Sealing between sleeve and jacket is made by an O-ring at top and by a glued on gasket for bottom.
  • Page 115 M 06.00 1D . . / 03.06...
  • Page 116 M 07.00 Cylinder head M 07.10 Rockers and decompression device – General: – Place 2 (A) or 3 (B) (washers during as- The decompression device works due to sembling of rocker shaft) dependant the fact that the rocker for the exhaust upon type of engine.
  • Page 117 M 07.00 M 07.10 1D . . / 03.06...
  • Page 118 M 07.00 Cylinder head M 07.20 Bumping clearance – General: The bumping clearance has to be checked and re-set after any replacement of a cylinder, piston, conrod, crankshaft or crankcase and with the engine cold. Bumping clearance to small: Damage to piston, cylinder head and valves.
  • Page 119 M 07.00 M 07.20 1D . . / 03.06...
  • Page 120 M 07.00 Cylinder head M 07.30 Cyl.-head and oil supply pipe - 3 - General: Inspection / repair: 1 D 60 - 80 only ! – Check cyl.-head for broken cooling fins, Due to variations in the depth of the steel cracks or any other damage.
  • Page 121 M 07.00 M 07.30 lb ft 1D30-31-35-40-41-50 50 1D60-80-81-90 2.5 mm 0.5 mm 2.5 mm 0.5 mm 1D . . / 03.06...
  • Page 122 M 07.00 Cylinder head M 07.40 Valves, valve guides and valve seats - 6 - Dismantling: Assembly: – Remove valve collets, spring cup, valve – Assemble in reverse sequence valve spring, spring retainer and valve stem stem seal cap, spring retainer, valve seal cap if fitted.
  • Page 123 M 07.00 M 07.40 Valve recession Type nom. (mm) (mm) 1D30-35-40 0.90 1.80 60-80 -1.45 1D31/41 0.60±0.1 1.00 – 1D50 1.00±0.1 1.40 1D81/90 0±0.1 0.40 D41/50 EPA II –0.60±0.1 –0.20 Radial play of valves Wear of valve guide Valve guides without recess for the valve stem seal cap Valve guides with recess for the valve stem seal cap 1D .
  • Page 124 M 08.00 Cover for cylinder head – General: There are engines with different breather systems in the field which are entirely different from one another. It is of utmost importance not to change the system as fitted ex-factory to avoid either blue smoke, high oil consumption or instability of engine speed.
  • Page 125 M 08.00 27 mm 52 mm 27 mm 1D . . / 03.06...
  • Page 126 M 09.00 Pushrods / Protection tubes - 3 - General: Pushrod tubes can be removed to replace the „O“-Rings in case of any oil leaks without removing the cylinder head. Dismantling: – Remove rocker shaft and rockers. – Remove pushrods 1. –...
  • Page 127 M 09.00 1D . . / 03.06...
  • Page 128 M 10.00 Oil pump / Governor tween marks on spring housing 13 and weight carrier 14 as specified. – Press weight carrier 14 firmly onto gear- - 4 - 15 - 16 - wheel unit 13/12 (flush) as specified. – Install (hook) governor weights 11 into General: corresponding roll pin location inside the The oil pump-governor assembly is built as...
  • Page 129 M 10.00 1D . . / 03.06...
  • Page 130 M 11.00 Timing cover - 10 - General: Assembly: Timing covers in connection with oil galleries – Pre-assemble timing cover/oil pump-gov- have been modified during production. ernor unit 5. (ref. M 10.00) Version I It is of utmost importance to observe the The oil gallery, i.e.
  • Page 131 M 11.00 S/Z/C 1D . . / 03.06...
  • Page 132 M 12.00 Extra fuel device – General: Assembly: The adjustment of fuel quantity injected in – Reverse in numerical sequence 6...3. accordance with power output is done by Apply locking agent as specified! turning the body part 7. – Hold body part 7 tight to avoid any Therefore remove complete extra fuel de- movement during assembly of closing vice only in case of a major overhaul i.e.
  • Page 133 M 12.00 9 mm 21 mm °C °F < 45 °C > 45 °C < 113 °F > 113 °F 14 mm 18 mm 26 mm 1D . . / 03.06...
  • Page 134 M 14.00 Fuel-injection equipment M 14.10 Fuel pressure pipe – Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: –Unscrew union nuts 1 and remove fuel pressure pipe with rubber bushing 3. NOTE: Ensure connector 2 remains tight during removal of fuel pressure pipe. Always use a wrench to hold connector 2 tight during disassembly of fuel pressure pipe !
  • Page 135 M 14.00 M 14.10 25 Nm 18 lb ft 1D . . / 03.06...
  • Page 136 M 14.00 Fuel-injection equipment M 14.20 Injector - 25 - Preparations: – Clean all parts carefully but do not use Ref.: M-Disassembly cross reference hard objects, brushes etc. scheme. Nozzle needle has to slide free by its own weight ! Dismantling: –...
  • Page 137 M 14.00 M 14.20 1D . . / 03.06...
  • Page 138 M 14.00 Fuel-injection equipment M 14.30 Injection pump - 28 - 33 - General: Preparations: The replacement of crankcase and / or Ref.: M-Disassembly cross reference camshaft requires a mandatory adjustment scheme. for timing and fuel quantity. For any field repair work i.e. replacement Functional check: of injection pump only, a standard replace- Before dismantling the injection pump a...
  • Page 139 M 14.00 M 14.30 400 bar 5 800 psi 1D . . / 03.06...
  • Page 140 M 14.00 Fuel-injection equipment M 14.30 Injection pump - 28 - 33 - Dismantling: NOTE: – Remove fuel supply. It is of utmost importance not to force the – Remove in numerical sequence 1...3. injection pump against the governor lever ! Hint: A small amount of „white out“...
  • Page 141 M 14.00 M 14.30 400 bar 5 800 psi 1D . . / 03.06...
  • Page 142 M 14.00 Fuel-injection equipment M 14.30 Injection pump - 28 - 33 - 38 - 39 - “Monoblock” injection pump (EPA II): From Serial No.: 1D41.21, 1D50.16, 1D81.24, 1D90S/Z.18, 1D90V/W.15 - Add numerical value at the crankcase (in mm, e.g. 1.6) and at the injection pump (in 1/10 mm, e.
  • Page 143 M 14.00 M 14.30 -38-39- 1D . . / 03.06...
  • Page 144 M 14.00 Fuel-injection equipment M 14.40 Roller tappet – Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove in numerical sequence 1...3. – Remove pressure plate 4 with „O“-Ring 5. Inspection / repair: – Check guide plate 2 and pressure plate 4 as well as roller tappet 6 for wear or any other damage.
  • Page 145 M 14.00 M 14.40 1D . . / 03.06...
  • Page 146 M 17.00 Flywheel – General: Flywheel markings: 1 D 30 - 31 - 35 - 40 - 41 - 50 only! OT = TDC / marks in degree Fixation by Allen screws M 10. 1 D 60 - 80 - 81 - 90 only! Version I - 1 D 80 only! Fixation by Allen screws M 12.
  • Page 147 M 17.00 1D . . / 03.06...
  • Page 148 M 26.00 Cowling / Air duct – Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Due to the different variants in connec- tion with electric start, handstart, anti- or clockwise direction of rotation etc. take care which parts like adaptor housing or any other parts in connection with the cowling system are fitted to avoid any mix up.
  • Page 149 M 26.00 A 1 D .. S / Z / T / U 1D . . / 03.06...
  • Page 150 M 31.00 Breather system – General: Version II Crankcase breathing is done via a rubber (as from middle of 1992 onwards) type diaphragm into the air intake port. Diaphragm separate in plastic housing. Whenever an engine is repaired, or indi- cates high lube oil consumption with blue Dismantling: exhaust smoke, the condition of the di-...
  • Page 151 M 31.00 7 8 6 1D . . / 03.06...
  • Page 152 M 32.00 Speed control – General: Dismantling: Speed control systems are different in – Remove grub screw 14. construction as far as their use in connec- – Remove in numerical sequence 7...11. tion with bowden or solenoid control is – Remove complete unit 18/12. concerned.
  • Page 153 M 32.00 11 10 8 6 13 III / IV 16 17 22 21 20 25 24 23 1D . . / 03.06...
  • Page 154 M 35.00 Capsule – Preparations:– Dismantling: – Remove all parts in question to get either access to the base engine as required or remove complete capsule in case a major overhaul has to be carried out. – In case the external capsule parts are removed, the internal air ducting has to be removed too.
  • Page 155 M 35.00 1D . . / 03.06...
  • Page 157 4. Tables 1D . . / 03.06...
  • Page 158 Injection equipment adjustment data Injection pump timing and injection pressure Models refers to engine speed begin of delivery injection pressure (A) 1 D ... Serial No. [min ° b TDC [bar] [psi] 30S,Z,T,U,C 10 – 18 31S,Z,T,U,C 10 – 17 n >...
  • Page 159 Injection equipment adjustment data Injection pump timing and injection pressure Models refers to engine speed begin of delivery injection pressure (A) 1 D ... Serial No. [min ° b TDC [bar] [psi] n ≤ 3000 81S,Z,T,U,C 10 – 19 20.0 + 1 90S,Z 10 –...
  • Page 160 Governor equipment General Compactors with low-idle speed stsbilisation Engine generator sets: PV 78 - PV 171 1D . . / 03.06...
  • Page 161 Governor equipment 3000 min 3600 min 1D . . / 03.06...
  • Page 162 General adjustment and testing data Bumping clearance Type S(mm) 1D30 - 80 0.65 - 0.75 1D41 / 50 0.60 - 0.65 1D81 0.75 - 0.80 1D90 0.80 - 0.85 Valve recession Type nom. (mm) (mm) 1D30-35-40 0.90 1.80 60-80 -1.45 1D31/41 0.60±0.1 1.00...
  • Page 163 General adjustment and testing data End-float of crankshaft 0.10 - 0.40 mm 0.10 - 0.40 mm 1D90 V/W: 0.05 - 0.10 mm Alternator air gap Standard: min 0,70 mm min. 0.70 mm 350 W “high output”: min. 1.20 mm 1D . . / 03.06...
  • Page 164 General adjustment and testing data Lub. oil quant. (Vol.) max. max. max. diff. tot. diff. tot. min. diff. tot. min. min. tot. diff. tot. diff. tot. diff. 1D30-31 1,20 0,40 2,80 2,00 4,40 3,60 A1D35 1,27 0,42 2,96 2,11 4,65 3,80 USqts 1D40-41...

  • Page 165: Torque Wrench Settings

    Torque wrench settings 1D 30-31-35-40-41-50 1D 60-80-81-90 lbf ft lbf ft 10.9 10.9 10.9 1D . . / 03.06...
  • Page 166 Torque wrench settings 1D 30 - 1D 90 lbf ft 1D30-31-35-40-41-50-81-90 40 – 50 30 – 37 1D60-80 50 – 70 37 – 52 1D . . / 03.06...
  • Page 167 Torque wrench settings General [Nm]: Nm ÷ 9.81(10) = kpm Nm ÷ 1.3558 = Lb ft Tensile quality Thread 10.9 12.9 M 10 M 12 M 14 M 16 M 18 M 20 M 22 1D . . / 03.06...
  • Page 168 Code designations in circuit diagrams (DIN 40719) Code Designation of electrical component Equipment box Equipment panel Automatic start-stop Starter protection module Temperature sensor Speed pulse sensor Oil pressure sensor Horn Capacitor Heater for fuel filter Fuse Battery Generator (alternator) Flywheel generator Indicator lamp, generator telltale Indicator lamp, oil pressure Indicator lamp, engine temperature...
  • Page 169 Code designations in circuit diagrams (DIN 40719) Code Designation of electrical component Operating hours counter Revolution counter Pressure display Preheat glowplug Heating flange Line resistor for preheat system Resistor Line resistor with thermal time switch Preheat starter switch (5 positions) Master switch Preheat starter switch (3 positions) Start-stop switch...
  • Page 170 HATZ wiring designations Terminal Designation Earth (ground) Generator B+ With alternator: D+ With flywheel generator: Terminal L at regulator Starter terminal 50 Oil pressure switch Temperature switch on cylinder head Preheat glowplug I Engine shutdown solenoid Preheat glowplug II Start-stop input Positive terminal for DC motor, precision speed control Negative terminal for DC motor, precision speed control Oil pressure sensor...
  • Page 171 Code marking with electrical wires Connector assignement Engine Connector assignement Wiring harness Socket connector Pin connector Socket connector Pin connector 0 Battery - (earth) 1 Battery + 2 Terminal L at regulator with flywheel generator 3 Starter terminal 50 4 Oil pressure switch 5 Temperature switch on cylinder head 6 Preheat glowplug 7 Engine shutdown solenoid...
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  • Page 181 Wiring diagramm for alternator testing Test of charging current: G G B+ L C W Test of no-load-voltage: G G B+ L C W 1D . . / 03.06...
  • Page 182 Alternator data 12 V 1 D 30 - 35 - 40 open coils (3 x 2) Charging current: Battery voltage 13.2 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D . . / 03.06...
  • Page 183 Alternator data 12 V 1 D 30 - 31 - 35 - 40 - 41 - 50 encapsulated coils Charging current: Battery voltage 13.2 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D .
  • Page 184 Alternator data 12 V 1 D 60 - 80 - 81 - 90 open as well as encapsulated coils Charging current: Battery voltage 13.2 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D .
  • Page 185 Alternator data 24 V 1 D 30 - 35 - 40 open coils (3 x 2) Charging current: Battery voltage 26.4 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D . . / 03.06...
  • Page 186 Alternator data 24 V 1 D 30 - 31 - 35 - 40 - 41 - 50 encapsulated coils Charging current: Battery voltage 26.4 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D .
  • Page 187 Alternator data 24 V 1 D 60 - 80 - 81 - 90 open as well as encapsulated coils Charging current: Battery voltage 26.4 V, normal operation temperature No-load voltage: measured between the yellow leads of the coils (voltage regulator disconnected) 1D .
  • Page 188 Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Indication Possible cause Remedial action Even shortly after Poor connections, open Eliminate open circuit, Battery is charging, the ter- circuit or contact resist- clean posts and clips, not being minal voltage drops ance in charging circuit, tighten loose terminals.
  • Page 189 Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Indication Possible cause Remedial action Insufficient current Sulphuric acid attacks Wash the posts and Post transfer, “bloom” metals (except lead). terminals down with hot terminals (white salt deposit). soda solution (but this corroded.
  • Page 190 Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Indication Possible cause Remedial action Voltage drops Battery is flat (dis- Recharge battery. Battery out- severely when a charged). put is too load is applied. low. Charging voltage is too Renew the voltage low: voltage regulator is regulator.
  • Page 191 Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Indication Possible cause Remedial action Generator indicator Poor connection (loose Check battery cables Starter does lamp is not on. or oxidised), break in and connections, clean not rotate cable or short to earth battery posts and ter- when (ground).
  • Page 192 Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Indication Possible cause Remedial action Lengthy period of Carbon brushes sticking. Renew carbon brushes Starter turns use without main- and brush holder guides. too slowly or tenance or in severe is unable to conditions.
  • Page 193 Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Indication Possible cause Remedial action Noise of starter Preheat/starting switch Reset the preheat/start- Starter con- turning. does not return auto- ing switch to 0 by force if tinues to matically from position 2 necessary and renew it.

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