Workshop manual 1D.. 438 202 01 - Printed in Germany Downloaded from www.Manualslib.
Downloaded from www.Manualslib.
Contents Foreword 1. General Engine illustrations Technical data Type plate data Lubrication oil circuit Special tools and workshop equipments Jointing material / Sealing and bonding agents 2. Additional equipments A 01.00 A 01.10 A 01.40 A 02:00 A 02.10 A 02.11 A 02.13 A 02.20 A 03.00 A 03.12 A 04.00 A 04.10 A 04.11 A 04.12 A 04.30 A 05.00 A 05.20 A 05.40 A 05.41 A 05.80 A 07.00 A 07.20 A 07.30 A 09.00 A 09.60 A 11.00 A 11.10 A 11.30 A 15.00 A 15.20 Downloaded from www.Manualslib.
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. Data sheets M 01.30 Oil sump and suction sieve Injection equipment adjustment data M 01.31 Oil sump 1 D 50 Governor equipment M 01.
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, including 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, gaskets, oil seals etc.
Downloaded from www.Manualslib.
1. General 1D . . / 03.06 Downloaded from www.Manualslib.
Engine illustrations Engine 1D30, 1D31, 1D40, 1D41, 1D50, 1D60, 1D80, 1D81, 1D90 S/Z/T/U 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 Cooling air inlet Oil pressure switch Dry type air cleaner Decompression lever Cooling air outlet Extra fuel device Injection pump Injector Cylinder head cover Cold start-oil priming device Lifting bracket, max. 120 kg / 265 lb Fuel filler cap Stop lever Timing cover Guiding shell for starting handle Fuel pressure pipe Governor 1D . . / 03.06 Downloaded from www.
Engine illustrations Noise-optimized version Engine A1D35, A1D40, A1D41 S/Z/T/U 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Air filter Oil pressure switch Injection pump bleeder valve Extra fuel device Air cowling cover Exhaust silencer Fuel tank Fuel filler cap Lifting bracket, max. 120 kg / 265 lb Cold start-oil priming device Decompression lever Fuel tank drain plug Oil filter (optional) Fuel filter Fuel feed pump (mounting pos.
Engine illustrations Fully encapsulated version Engine 1D30C, 1D31C, 1D40C, 1D41C, 1D60C, 1D80C, 1D81C 1 2 3 4 5 6 7 8 9 10 11 1 Capsule Decompression lever Cold start-oil priming device Combustion and cooling air intake Oil filter Cleaning opening Side panels Access for starting handle Lifting bracket, max. 120 kg / 265 lb Exhaust silencer, enclosed Engine flange 1D . . / 03.06 Downloaded from www.Manualslib.
Engine illustrations Engine 1D90 V/W 1 2 3 4 5 6 7 8 9 10 oil filler cap dipstick type plate combustion air intake dry type airfilter fuel tank drain plug cylinder head cover fuel filler cap cooling air inlet mechanical maintenance indicator 11 12 13 14 15 16 17 18 19 speed control lever oil filter fuel filter cooling air outle decompression levert exhaust silencer electric starter central plug f. electrical equipment oil drain plug 1D . . / 03.06 Downloaded from www.Manualslib.
Technical data Type Engine models 1D30.. 1D31.. 1D40.. A1D35.. A1D40.. 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 1 1 1 Bore / stroke mm 86/65 86/65 86/65 Cubic capacity cm3 377 377 377 Compression ratio 1D30: 20.5:1 1D31: 21.0:1 Direction of rotation looking at the flywheel 20.5:1 22.0:1* 20.5:1 1D . . S / Z / C counter-clockwise 1D . .
Technical data Type Engine models Mode of operation 1D41.. A1D41.. 1D50.. 1D60.. S, Z, T, U, C S, Z S, Z, T, U, C Air-cooled four-stroke diesel engine Combustion method Direct-injection Number of cylinders 1 1 1 Bore / stroke mm 90/65 97/70 88/85 Cubic capacity cm3 413 517 517 Compression ratio 20.0:1 20.0:1 20.5:1 Direction of rotation looking at the flywheel 1D . . S / Z / C counter-clockwise 1D . . T / U clockwise Cooling air required at 3000 min-1 m3/min 6.0 6.0 10.
Technical data Type Engine models Mode of operation 1D80.. 1D81.. 1D90. S, Z, T, U, C S, Z, V, W Air-cooled four-stroke diesel engine Combustion method Direct-injection Number of cylinders 1 1 Bore / stroke mm 100/85 104/85 Cubic capacity cm3 667 722 20.5:1 20.5:1 Compression ratio Direction of rotation looking at the flywheel 1D . . S / Z / C / V / W 1D . . T / U counter-clockwise clockwise Cooling air required at 3000 min-1 m3/min 10.5 10.
Type plate data 1D . . / 03.06 Downloaded from www.Manualslib.
EPA / Carb type plate data Engine family Type / Spec./ FDT 4 HZX L.667 V 83 1D81 Z 216B 13.0 Type code V = variable speed application C = constant speed application A = V + C as well Displacement (in cm3 or liters) Diesel engine (Benzin/gasoline = S) Manufactorer HZX = HATZ Manuf. year (X = 1999, Y = 2000, 1 = 2001,...) Static timing (begin of fuel delivery) Customer specification (only for special equipment) Variation Engine type Engine number 073 23 04 083019 Fabrication No.
Lubrication oil circuit 1D . . / 03.06 Downloaded from www.Manualslib.
Special tools and workshop equipments Engine series 1 D . . (SUPRA) Nr. 1 2 3 3 4 5 6 7 8 9 9 10 11 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25 1 Bezeichnung Ident-Nr.
Special tools and workshop equipments 1 3 2 8 9 4 10 5 11 6 12 13 7 14 15 19 18 16 17 22 18 23 19 20 24 21 25 1D . . / 03.06 Downloaded from www.Manualslib.
Special tools and workshop equipments Engine series 1 D . . (SUPRA) Nr. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1 Ident-Nr. 633 620 630 634 624 641 633 632 624 625 625 631 644 645 013 926 094 142 838 610 178 913 863 682 751 300 991 020 00 92 90 00 92 90 00 00 02 01 90 00 01 00 Bezeichnung Forcing screw for centrif.-clutch Oil pressure gauge 0... 6 bar Test nozzle 400 bar / 5800 psi Honing tool Rev.-counter for fuel press.
Special tools and workshop equipments 3 4 5 2 1 6 0 27 26 28 29 a 87 N O # * 50 15 86 30 31 87 - + T R SA 32 ma x. 20 10 30 75 40 0k g 34 33 35 38 36 37 39 1D . . / 03.06 Downloaded from www.Manualslib.
Jointing material / Sealing and bonding agents Sealing and bonding agents are available from HATZ for use in maintenance and/or repair 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.
2. Additional equipment 1D . . / 03.06 Downloaded from www.Manualslib.
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. – Unscrew respectively remove all retaining components in question, including fuel tank 4. – Remove fuel filter 5 with retaining components if necessary. Inspection / repair: – Visual inspection. – Check fuel tank for cracks and/or any other damage. – Check all rubber parts for ageing etc.
A 01.00 A 01.10 4 3 1 2 5 1D . . / 03.06 Downloaded from www.Manualslib.
A 01.00 Fuel A 01.40 Fuel feed pumps - 25 I. Fuel feed pump General: When connecting the fuel feed pump take care for arrangement of suction and supply hose. Preparations: – Disconnect fuel supply from fuel feed and injection pump. Dismantling: – Remove in numerical sequence 1 ... 3. NOTE: When removing the upper nut, make sure that the stud 4 does not turn in the crankcase as it serves as the anchor pin for the governor lever retainer spring.
A 01.00 A 01.40 25 1D . . / 03.06 Downloaded from www.Manualslib.
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. This avoid infiltrated air. flange also holds the glow plug in case a When fixing the oil bath air filter take pre-heating system is fitted.
A 02.00 A 02.10 9 7 8 6 5 3 4 1 2 1D . . / 03.06 Downloaded from www.Manualslib.
A 02.00 Combustion air A 02.11 Dry type air filters – Version A 02.11.1 Fixation of filter element and cover by flat washers and Hex.-nuts. Version A 02.11.2 Fixation of filter element separately by retaining plate, flat washers and Hex.-nuts. Preparations: – Dismantling: – Remove in numerical sequence 1...10. Preparations: – Dismantling: – Disconnect cable connection from heater flange if so fitted. – Remove in numerical sequence 1...12.
A 02.00 A 02.11 A 02.11.1 9 7 8 10 3 6 23 Nm 17 lb ft 4 5 5 78 76.5 78 4 1 2 4 A 02.11.2 1 11 23 Nm 17 lb ft 7 8 9 12 10 6 4 2 5 3 67.5 mm 1D30 - 1D40 64.7 mm 1D60 - 1D80 1D . . / 03.06 Downloaded from www.Manualslib.
A 02.00 Combustion air A 02.11 Dry type air filters – Version A 02.11.3 Fixation of filter element by front cover assembly. Version A 02.11.4 (A 1 D...) Fixation of filter element separately by retaining plate, flat washers and Hex.-nuts. Preparations: – Dismantling: – Disconnect cable connection from heater flange if so fitted. – Remove in numerical sequence 1...11. – If necessary dismantle cover retaining assembly to replace sealing sleeve (rubber) between centering and front cover.
A 02.00 A 02.11 A 02.11.3 10 6 11 7 9 1 3 4 5 2 8 A 02.11.4 15 6 12 14 3 8 9 10 2 13 4 5 B 11 7 64.7 1D . . / 03.06 Downloaded from www.Manualslib.
A 02.00 Combustion air A 02.13 Service indicators; vacuum gauges – Preparations: – Dismantling: – Remove in numerical sequence 1...2. – Remove in numerical sequence 3...6. Ensure not to lose flap valve 6! – Remove in numerical sequence 7...10. Hose pulled off from banjo hose nipple during removal. Hose nipple connection 16 may remain. 1 D 60 - 80 - 81 only: – Snip cable strap 11. – Remove in numerical sequence 10/12...15. Parts may remain as a unit. Inspection / repair: – Visual inspection.
A 02.00 A02.13 1D . . / 03.06 Downloaded from www.Manualslib.
A 02.00 Combustion air A 02.20 Pre-cleaners; cyclons – Version A 02.20.1 Cyclon fitted at bottom side inlet port. Front inlet port and through holes plugged. Version A 02.20.2 Cyclon fitted to front side inlet port. Bottom inlet port closed. Preparations: – Dismantling: – Loosen hose clip and remove cyclon 1. Preparations: – Dismantling: – Remove front cover 1 including cyclon system.Closing cap at bottom side remains. – Remove in numerical sequence 2...5. Inspection / repair: – Visual inspection.
A 02.00 A 02.20 A 02.20.1 A 02.20.2 3 4 5 2 1 1 1D . . / 03.06 Downloaded from www.Manualslib.
A 03.00 Exhausts A 03.12. Exhaust-silencers, high performance / Protection guard -2Version A 03.12.1 Exhaust silencer fitted in connection with studs, flat washers and hex.-nuts. Version A 03.12.2 Fixation by Allen screws. Protection guard General: The fixation of the guard has been modified to avoid breaks around the fixation due to excessive vibrations. Preparations: – Remove protection guard if so fitted. Preparations:– Dismantling: – Remove in numerical sequence 1...3/4. Dismantling: Version A 03.
A 03.00 A 03.12 A 03.12.1 A 03.12.2 3 5 2 5 1 3 4 3 2 2 23 Nm 17 lb ft A 12.30.1 1 A 12.30.2 1 1 2 2 1 2 4 4 4 4 3 3 3 1D . . / 03.06 Downloaded from www.Manualslib.
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. Preparations: – Dismantling: – Inspection / repair: – Visual inspection. – Check shaft 1 and handle 2 for wear and/or any other damage.Handle 2 can be replaced by removing and replacing snap ring 3.
A 04.00 A 04.10 A 04.10.1 2 3 1 A 04.10.2 4 7 8 12 11 3 10 15 14 13 A 16 15 2 1 9 6 5 1D . . / 03.06 Downloaded from www.Manualslib.
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 type A for 1 D.. S/Z/C engines. ATTENTION ! Take care, a worn shaft or broken handle can cause serious injuries. Preparations: – Dismantling: – Remove in numerical sequence 1...3. – Remove Allen screws 4 and cover 5. Remove cover carefully to avoid plate spring 11 jumping out. Risk of injury ! – Remove in numerical sequence 6...10.
A 04.00 A 04.10 A 04.10.1 2 3 1 A 04.10.2 4 7 8 12 11 3 10 15 14 13 A 16 15 2 1 9 6 5 1D . . / 03.06 Downloaded from www.Manualslib.
A 04.00 Start mechanical / pneumatic A 04.11 Starting handle supports – A 04.12 Cranking claws - 25 - General: Version A 04.11.1 Part without replaceable bushing. Version A 04.11.2 Part with replaceable bushing. ATTENTION ! Take care, a worn guiding shell can cause serious injuries. General: Version A 04.12.1 Part is bonded into camshaft. Version A 04.12.2 Parts fitted loose in camshaft. ATTENTION ! Take care, a worn or damaged cranking claw can cause serious injuries.
A 04.00 A 04.11 A 04.12 A 04.11.1 4 3 2 1 A 04.11.2 4 2 1 5 3 A 04.12.1 25 A 04.12.2 3 2 1 1D . . / 03.06 Downloaded from www.Manualslib.
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 driving elements 15 for wear and / or engines as follows: any other damage.
A 04.00 A 04.30 13 1 14 S/Z 4 3 5 12 11 4 10 9 m m 8 7 6 2 15 13 1 4 T/U 3 m 4 12 m 11 10 9 6 5 8 7 2 1D . . / 03.06 Downloaded from www.Manualslib.
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. – Place and tighten retaining items 8...7. Apply locking agent as specified ! – Rotate rope pulley 5 as specified 3 - 4 turns against the recoil spring tension and hold firm.
A 04.00 A 04.30 13 1 14 S/Z 4 3 5 12 11 4 10 9 m m 8 7 6 2 15 13 1 4 T/U 3 m 4 12 m 11 10 9 6 5 8 7 2 1D . . / 03.06 Downloaded from www.Manualslib.
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. 2 1D . . / 03.06 Downloaded from www.Manualslib.
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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: – Disconnect battery in sequence - / + – Disconnect cable connections as necessary, respectively remove retaining plate with voltage regulator depending on kind of equipment. Dismantling: – Remove in numerical sequence 1...6.
A 05.00 A 05.20 2 1 4 7 6 5 3 17 1D . . / 03.06 Downloaded from www.Manualslib.
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. Version A 05.40.2 The magnet segments are located on the flywheel by means of a machined location ring groove. Version A 05.40.3 The magnet segments are substituted by a magnet ring.
A 05.00 A 05.40 A 05.40.1 A 05.40.2 1 1 4 3 2 2 2.8 Nm 2.1 lb ft A 05.40.3 1 2 1D . . / 03.06 Downloaded from www.Manualslib.
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. – Remove in numerical sequence 1...5. Inspection / repair: – Visual inspection. – Check coils for wear and/or any other damage. Assembly: – Assemble in reverse sequence 4...1. Without spacers 5 and retaining nuts 1 loose. Adjustment: – Assemble flywheel.
A 05.00 A 05.41 A 05.41.1 4 5 3 2 1 min 0.7 mm 5 1D . . / 03.06 Downloaded from www.Manualslib.
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: – Remove flywheel and housing. Dismantling: – Disconnect electrical system. – Remove in numerical sequence 1...4. If necessary separate coils and support. Inspection / repair: – Visual inspection. – Check coils for wear and/or any other damage.
A 05.00 A 05.41 A 05.41.2 4 2 1 3 min 0.7 mm 1D . . / 03.06 Downloaded from www.Manualslib.
A 05.00 Start electrical A 05.41 Alternator / Coils – Version A 05.41.3 Coil encapsulated and fitted to crankcase. Fixation and adjustment of air gap by moving the coil in longitudinal slots. Preparations: – Remove flywheel. 1 D 30 - 31 - 35 - 40 - 41 - 50 only ! – Remove protection guard 1. Dismantling: – Disconnect electrical system. – Remove in numerical sequence 2...4. Inspection / repair: – Visual inspection. – Check coil for wear and/or any other damage. Assembly: – Assemble in reverse sequence 4...2.
A 05.00 A 05.41 1D . . / 03.06 Downloaded from www.Manualslib.
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: – Check part for broken teeth and/or other damage. Burrs can be filed down to a certain extent. Dismantling: – Check condition of ring gear before removal.
A 05.00 A 05.80 S/Z/C °C 1 °F 150 300 T/U 1D . . / 03.06 Downloaded from www.Manualslib.
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. Inspection / repair: – Visual inspection. – Check oil filter element 2 and rectangular rings 6. Maintenance according to instruction book. Assembly: – Assemble in reverse sequence 6...
A 07.00 A 07.20 A 07.20.1 6 2 5 1 6 3 4 A 07.20.2 6 2 5 1 6 3 4 1D . . / 03.06 Downloaded from www.Manualslib.
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 – dipsticks of different length may be fitted. Take care not to interchange these components by mistake during a repair and / or conversion job. Assembly: Ref.: Chapt. M 01.
A 07.00 A 07.30 1D30-31-35-40-41 2.8 l 4.4 l 1D60-80-81 3.2 l 4.5 l mm mm mm mm 60 25 58 204 60 + 60 25 118 285 mm mm mm mm 40 25 58 204 40 + 40 25 98 225 1D . . / 03.06 Downloaded from www.Manualslib.
A 09.00 Speed controls A 09.60 Low idle speed stabilization - 5 - 30 General: – Turn screw I so that lever 3 is facing Several engine applications require a very precise speed governing also in the range of vertical downwards (pin 7 is also in a vertical position). low idle, for example engines with hydraulic pumps in cold condition. For this case the low idle speed stabilization Fine tuning: (with engine running) is available. – Connect rev. counter - 30 – Set low idle speed to approx. 600 rpm.
A 09.00 A 09.60 7 I 5 II 5 III 3 I 2 1 II 4 III 6 29.5 I II 30.5 III 1D . . / 03.06 Downloaded from www.Manualslib.
A 11.00 Remote engine controls A 11.10 Stop devices – Version A 11.10.1 Stop lever S/Z/T/U Version A 11.10.2 Stop lever C. Preparations: – Dismantling: – Remove in numerical sequence 1...4. – Remove timing cover (M 11.00). – Remove lever 5. Bushing 6 may remain Preparations: – Dismantling: – Remove in numerical sequence 1...10. For further repair remove capsule parts as required to have access to standard engine respectively to bush 11 and lever 12.
A 11.00 A 11.10 A 11.10.1 5 1 2 3 4 6 = = A 11.10.2 11 12 10 9 8 5 7 5 4 6 1 2 3 1D . . / 03.06 Downloaded from www.Manualslib.
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. - Opening pressure on cold engine 0.4 bar - Shut-off reaction pressure approximately 1.0 bar at 3000 rpm - Idle speed of 800 rpm admissible up to oil level "min".
A 11.00 A 11.30 Run: Relief lever Relief lever Feed Return 1D . . / 03.06 Downloaded from www.Manualslib.
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 dismantling of flywheel 8. Inspection / repair: – Visual inspection. – Check housing for cracks or any other damage. Assembly: – Assemble in reverse sequence 9...1. – Assemble starter motor if so fitted. 2 1D . . / 03.06 Downloaded from www.
A 15.00 A 15.20 7 8 2 9 5 1 4 1 3 5 4 6 5 4 1D . . / 03.06 Downloaded from www.Manualslib.
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3. Basic engine 1D . . / 03.06 Downloaded from www.Manualslib.
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M - Basic engine M-Disassembly cross reference scheme 1D . . / 03.06 Downloaded from www.Manualslib.
M 01.00 Crankcase M 01.10 Crankcase, nozzle and bearings - 9 - 13 Preparations: Ref.: M-Disassembly cross reference scheme. Oil spray nozzle – Install and screw nozzle 3 firmly in place so oil spray will be directed down directly on the camshaft. Apply high strength locking agent E. Clock-wise engines (version T/U) are equipped with an additional oil spray nozzle in the timing cover. It points to the middle of the camshaft bearing bore (view to inside of timing cover).
M 01.00 M 01.10 1D . . / 03.06 Downloaded from www.Manualslib.
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 up to series no.: 1 D 30.15 A 1 D 35.13 1 D 31.13 A 1 D 40.12 1 D 40.16 A 1 D 41.11 1 D 41.13 1 D 60.22 1 D 81.15 1 D 80.21 1 D 90.10 Variant II from series no. on: 1 D 30.16 1 D 40.17 1 D 31.14 1 D 41.14 1 D 60.23 1 D 81.16 1 D 80.22 1 D 90.11 1 D 90 V/W.
M 01.00 M 01.11 Variante I 2 2 1 1 Variante II 2 3 2 2 4 5 6 1 1D . . / 03.06 Downloaded from www.Manualslib.
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 follower bracket 6. The cam follower bracket as well as the thrust plate are fitted together to the crankcase by Allen screws.
M 01.00 M 01.20 4 3 25 2 10 T/U 1 8 10 5 25 2 Pos. 1 4 4 S/Z/C lb ft 8 M9 M8 M8 M6 10.9 10.9 8.8 10.9 40 35 24 14 30 26 18 10 1 M6 8.8 11 8 9 7 6 8 Nm 3 2 25 1 3 2 25 III II 0.9 mm 1.05 mm 1.20 mm 10 M9 I 10 M8 M8 3.5 mm 9 9 8 9 8 8 M6 0.10 - 0.40 mm 1D90 V/W: 0.05 - 0.10 mm 1D . . / 03.06 Downloaded from www.Manualslib.
M 01.00 Crankcase M 01.20 Crankshaft-thrustplate and cam followers - 25 Crankshaft thrustplate General: It is of utmost importance to observe the specified torque settings in connection with the different type tensile strength of the respective retaining screws. Version I Fixation by two each retaining screws M 6 - M 8 without spacer shims. Version II Fixation by retaining screws M 8. A = Point of support recessed in crankcase, spacer shims 10 = 3.5 mm.
M 01.00 M 01.20 4 3 25 2 10 T/U 1 8 10 5 25 2 Pos. 1 4 4 S/Z/C lb ft 8 M9 M8 M8 M6 10.9 10.9 8.8 10.9 40 35 24 14 30 26 18 10 1 M6 8.8 11 8 9 7 6 8 Nm 3 2 25 1 3 2 25 III II 0.9 mm 1.05 mm 1.20 mm 10 M9 I 10 M8 M8 3.5 mm 9 9 8 9 8 8 M6 0.10 - 0.40 mm 1D90 V/W: 0.05 - 0.10 mm 1D . . / 03.06 Downloaded from www.Manualslib.
M 01.00 Crankcase M 01.30 Oil sump and suction sieve – Preparations: Ref.: M-Disassembly cross reference scheme. Oil sump Dismantling: – Remove in numerical sequence 1...2. – Remove oil sump 3 using a plastic hammer. Inspection / repair: – Check oil sump for possible cracks, deformations, flatness of sealing surface and any other damage. Assembly: – Assemble in reverse sequence 3...1. Apply sealant and locking agent as specified.
M 01.00 M 01.30 6(R) b 1 1D30-31-35-40-41-50 1D60-80-81-90 b (mm) S/Z/C 25 45 T/U 1D . . / 03.06 Downloaded from www.Manualslib.
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. – Pay attention to correct positioning of fastening screws! Note: A = M 8 x 40 shim ring 8 x 14 x 1 B = M 8 x 30 shim ring 8 x 14 x 1 C = M 8 x 30 Z3 D = M 6 x 25 flat washer 6,4 E = M 6 x 16 flat washer 6,4 – Fit screws with screw retention D in position D and E.
M 01.00 M 01.31 H 3 B C A 1 B C D E D D C 2 3 1D . . / 03.06 Downloaded from www.Manualslib.
M 01.00 Crankcase M 01.40 Base plate and oil pressure relief valve – Preparations: Ref.: M-Disassembly cross reference scheme. Oil pressure relief valve Dismantling: – Remove in numerical sequence 6...8. Base plate Inspection / repair: – Check base plate for flatness, cracks or any other damage. Inspection / repair: – Check relief valve for contamination and/or any other damage. Assembly: – Apply sealing agent B onto crank case (see drawing) – Assemble in reverse sequence 5...1.
M 01.00 M 01.40 4 8 3 7 6 5 2 1 a a 23 Nm 17 lb ft 1D90V/W: b D d c a 9 B 1D . . / 03.06 Downloaded from www.Manualslib.
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. 3 1D . . / 03.06 Downloaded from www.Manualslib.
M 01.00 M 01.50 S [mm] 1D50 1D30-31-35 40-41-50 1D60-8081-90 1.9-2.2 2.5 04219200 2.3-2.6 3.0 04219300 2.7-3.1 3.5 04150300 50458400 1D30-3135-40-41 50392000 50459800 1D60-8081- 90 04084500 S 1D . . / 03.06 Downloaded from www.Manualslib.
M 02.00 M 02.10 g h Wear and grinding dimensions 1 D 30 - 31 - 35 - 40 - 41 - 50 e f Rt 1 - 4 0.3 Hardness at bearing journals 600 - 680 HV 100 / 55 -60 HRC 0.3 R3.3-3.5 c b k a b l d R2.4-2.6 R2.4-2.6 i Nom. value (mm) 0.3 Wear tolerance Grinding dimensions (mm) – 0.5 (mm) Wear tolerance – 0.5 (mm) a* Ø 55.01 - 55.05 55.15 54.51 - 54.55 54.65 b Ø 54.97 - 54.99 54.90 54.47 - 54.49 54.40 a-b 0.02 - 0.08 0.25 0.02 - 0.08 0.25 c* Ø 55.05 - 55.09 55.20 54.55 - 54.59 54.
M 02.00 M 02.10 g h 13.5 0.008 - 0.01 0.3 0.3 Wear and grinding dimensions 1 D 60 - 80 - 81 - 90 (9.5) e f 19 Rt 1 - 4 Hardness at bearing journals 600 - 680 HV 100 / 55 -60 HRC 0.3 R4.0-4.2 c b k a b l d R2.8-3.0 R2.8-3.0 i Nom. value (mm) 0.3 Wear tolerance Grinding dimensions (mm) – 0.5 (mm) Wear tolerance – 0.5 (mm) a* Ø 65.02 - 65.06 65.15 64.52 - 64.56 64.65 b Ø 64.97 - 64.99 64.90 64.47 - 64.49 64.40 a-b 0.03 - 0.09 0.25 0.03 - 0.09 0.25 c* Ø 65.06 - 65.09 65.
M 02.00 Crankshaft M 02.20 Crankshaft gearwheel and stubshafts - 12 - 14 General: Crankshaft gearwheel respectively stubshaft are shrink fitted. Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove gearwheel 1 respectively stubshaft 2. For removal use tool - 14 Inspection / repair: – Check gearwheel or stubshaft for wear or any other damage. Assembly: – Put engine onto flywheel side (flywheel fitted) to avoid damaging of flywheel side thrust plate.
M 02.00 M 02.20 1D . . / 03.06 Downloaded from www.Manualslib.
M 02.00 Crankshaft M 02.30 Crankshaft / Wear sleeve – Preparations: Ref.: M-Disassembly cross reference scheme. Assembly: – Assemble in reverse sequence 3...1. Torque to specification ! Dismantling: – Remove in numerical sequence 1...3. Remove counter weight through cylinder bore. Shaft Repair Sleeve 1 D 60 - 80 - 81 - 90 only! In case the running surface position of the oil seal ring shows excessive wear a repair sleeve can be used. Inspection / repair: – Visual inspection.
M 02.00 M 02.30 5 4 3 2 1 Nm lb ft 1D30-31-35-40-41-50 40 30 1D60-80-81-90 75 55 1D . . / 03.06 Downloaded from www.Manualslib.
M 03.00 Bearing flange - 11 General: At the very early stages of serial production certain engines have been equipped with a reverse-run safety device fitted into the bearing flange. This device was later replaced by the antikick-back starting handle. In case of any failure respectively repair and/or replacement contact your nearest HATZ-Distributor. Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: It is of utmost importance to remove the two cyl.
M 03.00 1D . . / 03.06 Downloaded from www.Manualslib.
M 03.00 Bearing flange M 03.10 Bearing flange 1D90V / W Dismantling / Wear measurements: – see M 03.00 General: The crankshaft axial clearance of engines 1 D 90 V/W is limited at the bearing flange 1 in both directions. Additionally, to the thrust ring 2 a second thrust ring 3, collar bush 4 and between flywheel and crankshaft a washer have been fitted. In order to prevent the thrust ring 3 from rotating two spring pins 6 have been pressed into the bearing flange 1 in an excess length of 2 mm.
M 03.00 M 03.10 5 8 4 10 3 1 9 2 6 min. 0,05 mm, max. 0,10 mm ! 7 4 1 7 9 3 6 2 1D . . / 03.06 Downloaded from www.Manualslib.
M 04.00 Camshaft and balancer unit M 04.00 Camshaft and balancer unit -8Preparations: Ref.: M-Disassambly cross reference scheme. Camshaft Dismantling: – Lift cam followers away from camshaft. If possible put engine onto flywheel. – Remove (pull) camshaft 1. Inspection / repair: – Check running surfaces as well as oil seal position and gear teeth for wear Assembly: Install camshaft 1 firmly into bore position. Ensure gear timing marks match! 3 1D . . / 03.06 Downloaded from www.Manualslib.
M 04.00 1D30-31-35-40-41-50 ~ 50mm 1D60-80-81-90 ~ 60mm 1 ˚F ˚C 300 -400 150 -200 3 3 8 4 1 2 2 2 3 3 1D . . / 03.06 Downloaded from www.Manualslib.
M 05.00 Piston with connecting rod M 05.10 Piston and piston rings - 20 General: 1 D 80 - 81 only! Pistons are different in their combustion bowl cavity. 1 D 40 only! Pistons available for two different compression ratios. Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove circlips 1. – Remove (push) gudgeon pin 2 and lift off piston 3. – Remove piston rings. For removal use tool - 20 Inspection / repair: – Check piston rings for wear or any other damage.
M 05.00 M 05.10 1 D 40 ε 20.5 22.0 h (mm) 12.0 10.9 h I max. 0.20 mm II max. 0.15 mm III max. 0.10 mm 20 1 3 1D80 2 1D81 1D . . / 03.06 Downloaded from www.Manualslib.
M 05.00 Piston with connecting rod M 05.20 Connecting rod – General: Connecting rods can be fitted either way as far as matching-No. and engine speed is concerned. The broaching cut as well as an additional pin location are the basis for the location top to bottom. Don't interchange parts i.e. matching-Nos. have to correspond ! As of series stand: 1D30.17, 1D31.15, 1D40.18, 1D41.15, 1D50.10, 1D60.20, 1D80.20, 1D81.13, 1D90.10, 1D90V/W.
M 05.00 M 05.20 100 mm 0.025 mm 5 2 3 1 Nm lb ft 1D30-31-35-40-41-50 40 30 1D60-80-81-90 85 63 nom. (mm) max. (mm) aØ 52.02 - 52.06 52.15 bØ 55.00 - 55.02 55.05 cØ 28.00 - 28.01 28.03 dØ 25.03 - 25.04 25.10 nom. (mm) max. (mm) aØ 60.02 - 60.06 60.15 bØ 63.00 - 63.02 63.05 cØ 33.00 - 33.02 33.03 dØ 30.03 - 30.04 30.12 1D30-31-35-40-41-50 c d 1D60-80-81-90 b a 4 1D . . / 03.06 Downloaded from www.Manualslib.
M 06.00 Cylinder - 21 - 29 Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove (pull) cylinder carefully from piston. Inspection / repair: – Check cylinder for broken cooling fins, wear, score marks or any other damage. Index of piston ring wear To be measured at the very bottom end of the cylinder where normally no wear at all occurs during operation. – Insert respective piston ring which should be checked into the cylinder.
M 06.00 d a Tab. A dim.(max.) mm 1D30-31 1D35-40 1D41-50-60 1D80 1D81-90 a 0.45 0.45 0.55 0.60 b a 0.8 1.0 1.2 1.2 0.45 0.45 0.55 0.60 b a 1.4 1.6 1.8 1.8 0.40 0.40 0.40 0.45 b 1.2 1.4 1.6 1.6 b Tab. B dim. d 1D30-31-35-40 1D41 1D60 1D80-81 1D90 nom. 86.00 - .01 90.00 - .01 88.00 - .01 100.00 - .01 104.00 - .01 + 0.5 86.50 - .51 90.50 - .51 88.50 - .51 100.50 - .51 104.50 - .01 — 87.00 - .01 91.00 - .01 89.00 - .01 101.00 - .01 + 1.0 max. Ra (μ) + 0.
M 06.00 Cylinder Cylinder 1D50: For 1D50 engines, a press-fit-sleeve is assembled to aluminium cooling jacket, hence in case of wear a sleeve replacement is possible. Sealing between sleeve and jacket is made by an O-ring at top and by a glued on gasket for bottom. During assembly of sleeve to jacket, apply grease K in the lower region in order to avoid damages to the O-ring. 3 1D . . / 03.06 Downloaded from www.Manualslib.
M 06.00 K 1D . . / 03.06 Downloaded from www.Manualslib.
M 07.00 Cylinder head M 07.10 Rockers and decompression device – General: The decompression device works due to the fact that the rocker for the exhaust valve is eccentrically supported on the rocker shaft. The axial fixation of the rocker shaft is executed as follows: 1 D 60 - 80 - 81 by a spring loaded pin (A) 1 D 30 - 31 - 35 - 40 - 41 - 50 by washers and circlips (B). The radial fixation of the rocker shaft is executed due to an adjustable spring loaded ball stop. Dismantling: – Set the engine to T.D.C.
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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. Bumping clearance to big: Engine loses power and starting ability. Preparations: Ref.: M-Disassembly cross reference scheme.
M 07.00 M 07.20 1D . . / 03.06 Downloaded from www.Manualslib.
M 07.00 Cylinder head M 07.30 Cyl.-head and oil supply pipe -3General: 1 D 60 - 80 only ! Due to variations in the depth of the steel anchors in the crankcase in connection with thread reach certain engines have thinner washers fitted to the crankcase front side. It is of utmost importance to have the correct type washers fitted in the same position as fitted ex-factory ! Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove rocker shaft and rockers.
M 07.00 M 07.30 Nm lb ft 1D30-31-35-40-41-50 50 37 80 59 1D60-80-81-90 1 4 2 3 4 2.5 mm 1 2 0.5 mm 0.5 mm 2.5 mm 1D . . / 03.06 Downloaded from www.Manualslib.
M 07.00 Cylinder head M 07.40 Valves, valve guides and valve seats -6Dismantling: – Remove valve collets, spring cup, valve spring, spring retainer and valve stem seal cap if fitted. For removal use tool - 6 Inspection / repair: – Check all parts in question for wear or any other damage like cyl.-head cracks etc. especially for the following conditions: Valve recession – After re-installing the valves check the valve recession as specified.
M 07.00 M 07.40 Valve recession Type + – nom. max (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 0±0.1 0.40 –0.60±0.1 –0.20 1D81/90 D41/50 EPA II 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 . . / 03.06 Downloaded from www.Manualslib.
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. Version I Breather orifice as indicated, breather system internal. Version II Breather orifice as indicated, breather system internal. Version III Breather orifice as indicated, breather system external.
M 08.00 27 mm 52 mm I II 27 mm III 1 2 3 4 1D . . / 03.06 Downloaded from www.Manualslib.
M 09.00 Pushrods / Protection tubes -3General: 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. – Release and move circlip 6 approx. 30 mm toward cyl.-head. – Press pushrod tube unit 2 firmly down and remove (tilt) complete unit out of its seat position in cyl.-head. The complete unit 2 may remain preassembled, respectively dismantled if necessary.
M 09.00 3 2 6 5 1 3 4 3 1D . . / 03.06 Downloaded from www.Manualslib.
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 weight carrier 14. a unit and fitted inside the timing cover. Governor springs can be replaced without – Assemble in reverse sequence 10...9.
M 10.00 1D . . / 03.06 Downloaded from www.Manualslib.
M 11.00 Timing cover - 10 General: Timing covers in connection with oil galleries have been modified during production. Version I The oil gallery, i.e. the oil supply to the camshaft bearing, is fully cast-in. Version II The oil galleries, i.e. the oil supply to the camshaft bearing, are milled as open channels and therefore covered by a new constructed oil pump cover. Note: Clock-wise engines (version T/U) are equipped with an additional oil spray nozzle in the timing cover.
M 11.00 10 6 S/Z/C T/U 5 4 3 2 1 5 1D . . / 03.06 Downloaded from www.Manualslib.
M 12.00 Extra fuel device – General: The adjustment of fuel quantity injected in accordance with power output is done by turning the body part 7. Therefore remove complete extra fuel device only in case of a major overhaul i.e. the device 2, at least the body 7, should remain if possible. NOTE: Removal of complete extra fuel device requires re-adjustment of fuel setting. I. Standard extra fuel device Function Engine at stand-still (no oil pressure) means the fuel limit stop pin is in open position i.e.
M 12.00 3 4 A 5 B 9 mm 21 mm 6 2 7 8 15 23 1 < 45 °C < 113 °F °C A °F > 45 °C > 113 °F C B 14 mm 18 mm 26 mm 1D . . / 03.06 Downloaded from www.Manualslib.
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 ! Inspection / repair: – Check for fractures or chafing. – Check conditions of sealing surfaces.
M 14.00 M 14.10 1 25 Nm 18 lb ft 4 3 1 2 1D . . / 03.06 Downloaded from www.Manualslib.
M 14.00 Fuel-injection equipment M 14.20 Injector - 25 Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove in numerical sequence 1...5. – Loosen and remove injector 6 by turning or pulling. For removal use tool - 25 – Remove seal ring 7 either from injector or cyl.-head. Inspection / repair: – Check nozzle body for overheating or plugged spray holes. If possible test injector using a nozzle tester or contact your nearest HATZ-Distributor or any other authorized workshop.
M 14.00 M 14.20 1D . . / 03.06 Downloaded from www.Manualslib.
M 14.00 Fuel-injection equipment M 14.30 Injection pump - 28 - 33 General: The replacement of crankcase and / or camshaft requires a mandatory adjustment for timing and fuel quantity. For any field repair work i.e. replacement of injection pump only, a standard replacement of the injection pump would be within the ex-factory adjusted values as long as no changes in timing (shims) and / or fuel setting (extra fuel device) have been done.
M 14.00 M 14.30 28 400 bar 5 800 psi B 3 1 2 A 1D . . / 03.06 Downloaded from www.Manualslib.
M 14.00 Fuel-injection equipment M 14.30 Injection pump - 28 - 33 Dismantling: – Remove fuel supply. – Remove in numerical sequence 1...3. Inspection / repair: – Check control sleeve A for free movement. NOTE: Repairs in connection with the injection pump should be carried out by a HATZDistributor or any other authorized workshop.
M 14.00 M 14.30 28 400 bar 5 800 psi B 3 1 2 A 1D . . / 03.06 Downloaded from www.Manualslib.
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. g.
M 14.00 M 14.30 1,6 -38-39- 1D . . / 03.06 Downloaded from www.Manualslib.
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. – Check surface condition of roller in connection with camshaft. NOTE: The roller tappet 6 must be replaced as a complete unit. Pressure plate 4 available as spare part.
M 14.00 M 14.40 3 4 5 6 2 1 1D . . / 03.06 Downloaded from www.Manualslib.
M 17.00 Flywheel – General: 1 D 30 - 31 - 35 - 40 - 41 - 50 only! Fixation by Allen screws M 10. 1 D 60 - 80 - 81 - 90 only! Fixation by Allen screws M 12. Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Remove in numerical sequence 1...3/4. For removal always use two studs (≈ 220 mm) to prevent the flywheel from falling. Ensure not to lose centering bushing ! Inspection / repair: – Check and clean cooling fan if necessary.
M 17.00 1D . . / 03.06 Downloaded from www.Manualslib.
M 26.00 Cowling / Air duct – Preparations: Ref.: M-Disassembly cross reference scheme. Dismantling: – Due to the different variants in connection 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. Inspection / repair: – Check sealing strips as well as all other rubber parts for ageing etc.
M 26.00 A 1 D .. S / Z /T / U C 1D . . / 03.06 Downloaded from www.Manualslib.
M 31.00 Breather system – General: Crankcase breathing is done via a rubber type diaphragm into the air intake port. Whenever an engine is repaired, or indicates high lube oil consumption with blue exhaust smoke, the condition of the diaphragm should be checked. Preparations: Ref.: M-Disassembly cross reference scheme. Version I Diaphragm fitted into cyl.-head. Dismantling: – Carefully remove aluminium cover 1. – Remove diaphragm 2.
M 31.00 I 1 2 II 7 8 6 3 4 5 1D . . / 03.06 Downloaded from www.Manualslib.
M 32.00 Speed control – General: Speed control systems are different in construction as far as their use in connection with bowden or solenoid control is concerned. Preparations: Ref.: M-Disassembly cross reference scheme. Version I Early serial production. Unsuitable in connection with bowden or solenoid control due to no frictionless movement of the speed control. Version II Early serial production. Suitable in connection with bowden or solenoid control.
M 32.00 12 9 11 10 8 7 I 3 4 14 6 13 III / IV 5 19 18 1 2 16 17 II 22 21 20 5 25 24 23 15 4 4 4 III IV 4 4 7.5 7.5 1D . . / 03.06 Downloaded from www.Manualslib.
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. Inspection / repair: – Check sealing strips as well as all other rubber parts for ageing etc.
M 35.00 1D . . / 03.06 Downloaded from www.Manualslib.
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4. Tables 1D . . / 03.06 Downloaded from www.Manualslib.
Injection equipment adjustment data Injection pump timing and injection pressure Models refers to engine speed (A) 1 D ... 30S,Z,T,U,C 31S,Z,T,U,C 40S,Z,T,U,C 41S,Z,T,U,C Serial No. 10 – 18 10 – 17 10 – 19 10 – 17 [min-1] ° b TDC [bar] [psi] n > 3000 n ≤ 3000 23.0 +1 20.0 +1 200+8 2900+110 35S,Z 10 – 16 n ≤ 3000 16.0 + 1 200+8 2900+110 41S,Z,T,U,C 18 – 20 1500 ≤ n ≤ 1900 1900 < n ≤ 2400 2400 < n ≤ 3000 n > 3000 C: n > 3000 10.0 12.5 14.0 17.5 15.
Injection equipment adjustment data Injection pump timing and injection pressure Models refers to engine speed (A) 1 D ... 81S,Z,T,U,C 90S,Z 90 V,W Serial No. 10 – 19 10 – 14 10 [min-1] n ≤ 3000 n > 3000 ° b TDC 20.0 + 1 23.0 + 1 81S,Z,C 20 – 23 1500 ≤ n ≤ 1800 1800 < n ≤ 2700 2700 < n ≤ 3000 3000 < n ≤ 3600 8.0 + 1 10.0 + 1 13.0 + 1 15.0 + 1 81S,Z,C EPA II 24 begin of delivery injection pressure [bar] [psi] 235+8 3400+110 270+12 3870+160 8.0 + 1 9.0 + 1 10.0 + 1 11.0 + 1 12.0 + 1 13.
Governor equipment General Compactors with low-idle speed stsbilisation Engine generator sets: PV 78 - PV 171 4 1D . . / 03.06 Downloaded from www.Manualslib.
Governor equipment 3000 min-1 l d D S 3600 min-1 l l d D d D S 1D . . / 03.06 Downloaded from www.Manualslib.
General adjustment and testing data Bumping clearance S 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. max (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 0±0.1 0.40 D41/50 EPA II –0.60±0.1 –0.20 Type In Out (mm) (mm) 1D30 - 81 0.1+0.05 0.2+0.05 1D41 0.2+0.05 0.2+0.05 1D90 0.3+0.05 0.3+0.05 1D81/90 Tappet clearance (cold) 4 1D . . / 03.
General adjustment and testing data End-float of crankshaft 0.10 0.10 -- 0.40 0.40 mm 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 Downloaded from www.Manualslib.
General adjustment and testing data Lub. oil quant. (Vol.) max. max. diff. min. tot. max. diff. min. tot. diff. tot. min. 1D30-31 A1D35 1D40-41 tot. diff. tot. diff. tot. diff. l 1,20 0,40 2,80 2,00 4,40 3,60 USqts 1,27 0,42 2,96 2,11 4,65 3,80 l 1,90 0,90 3,20 2,20 4,50 3,50 USqts 2,01 0,95 3,38 2,32 4,76 3,70 l 1,50 0,50 USqts 1,58 0,53 l 1,60 0,70 USqts 1,69 0,74 1D60-80-81-90 1D50 1D90V/W Lub. oil pressure min-1 ± 10% norm. min.
Torque wrench settings 1D 30-31-35-40-41-50 Nm lbf ft 1D 60-80-81-90 Nm lbf ft 40 30 75 55 40 30 85 63 50 37 80 59 2,8 2 2,8 2 68 50 M12 115 85 M14 190 140 M10 M9 10.9 40 30 40 30 M8 10.9 35 26 35 26 M8 8.8 24 18 24 18 M6 10.9 14 10 14 10 1D . . / 03.06 Downloaded from www.Manualslib.
Torque wrench settings 1D 30 - 1D 90 1D30-31-35-40-41-50-81-90 1D60-80 4 1D . . / 03.06 Downloaded from www.Manualslib.
Torque wrench settings General [Nm]: Nm ÷ 9.81(10) = kpm Nm ÷ 1.3558 = Lb ft Tensile quality 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 1D . . / 03.06 Downloaded from www.Manualslib.
Code designations in circuit diagrams (DIN 40719) Code Designation of electrical component A A A A 1 2 3 4 Equipment box Equipment panel Automatic start-stop Starter protection module B B B B 1 2 3 4 Temperature sensor Speed pulse sensor Oil pressure sensor Horn C1 Capacitor E1 Heater for fuel filter F1 Fuse G1 G2 G3 Battery Generator (alternator) Flywheel generator H H H H H H H H 1 2 3 4 5 6 7 8 Indicator lamp, generator telltale Indicator lamp, oil pressure Indicator lamp, engine temper
Code designations in circuit diagrams (DIN 40719) Code Designation of electrical component P1 P2 P3 Operating hours counter Revolution counter Pressure display R R R R R 1 2 3 4 5 Preheat glowplug Heating flange Line resistor for preheat system Resistor Line resistor with thermal time switch S S S S S S S S S S S S 1 2 3 4 5 6 7 8 9 10 11 12 Preheat starter switch (5 positions) Master switch Preheat starter switch (3 positions) Start-stop switch Speed control switch Engine temperature switch Oil pr
HATZ wiring designations Terminal 4 Designation 0 Earth (ground) 1 Generator B+ 2 With alternator: D+ With flywheel generator: Terminal L at regulator 3 Starter terminal 50 4 Oil pressure switch 5 Temperature switch on cylinder head 6 Preheat glowplug I 7 Engine shutdown solenoid 8 Preheat glowplug II 9 Start-stop input 10 Positive terminal for DC motor, precision speed control 11 Negative terminal for DC motor, precision speed control 12 Oil pressure sensor 13 * * * reserved f
Code marking with electrical wires Connector assignement Engine Socket connector Connector assignement Wiring harness Pin connector Pin connector 0 1 2 3 4 5 6 7 14 22 24 28 Socket connector Battery - (earth) Battery + Terminal L at regulator with flywheel generator Starter terminal 50 Oil pressure switch Temperature switch on cylinder head Preheat glowplug Engine shutdown solenoid Speed control solenoid - holding-on winding Terminal W for engine-speed measurement Terminal C with regulator on flywheel
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Downloaded from www.Manualslib.com manuals search engine 1D . . / 03.
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Downloaded from www.Manualslib.com manuals search engine 1D . . / 03.06 4 C L B+ G/~ G/~ W G U F1 31 – + 30 Startvorbereitung / PRE-START PHASE Motor startet / ENGINE START START STOP RESET LAMP.
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Downloaded from www.Manualslib.com manuals search engine 1D . . / 03.
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Wiring diagramm for alternator testing Test of charging current: 15 30 1 P 30 24 I III II A _ M 50 2 0 3 _ + 50a G G B+ L C W 22 24 2 G Test of no-load-voltage: 15 30 1 30 0 P M 24 I 50 2 III II 3 _ + 50a G G B+ L C W 22 2 24 V ~ G 1D . . / 03.06 Downloaded from www.Manualslib.
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) 4 1D . . / 03.06 Downloaded from www.Manualslib.
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 . . / 03.06 Downloaded from www.Manualslib.
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) 4 1D . . / 03.06 Downloaded from www.Manualslib.
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 Downloaded from www.Manualslib.
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) 4 1D . . / 03.06 Downloaded from www.Manualslib.
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 . . / 03.06 Downloaded from www.Manualslib.
Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Indication Even shortly after Battery is charging, the ternot being charged suf- minal voltage drops ficiently or at rapidly to 7 V on systems with 12 V all, or is nominal voltage. being discharged too rapidly. Possible cause Poor connections, open circuit or contact resistance in charging circuit, short-circuit in line. Remedial action Eliminate open circuit, clean posts and clips, tighten loose terminals.
Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Post terminals corroded. Acid level too low. Indication Possible cause Insufficient current Sulphuric acid attacks transfer, “bloom” metals (except lead). (white salt deposit). Remedial action Wash the posts and terminals down with hot soda solution (but this must not enter the battery!), rinse with cold water and apply acidresistant grease. Acid level less than 10 mm (0.4 in) above top of cell plates.
Troubleshooting chart - electrical system Troubleshooting at the battery Malfunction Battery output is too low. Indication Voltage drops severely when a load is applied. Possible cause Battery is flat (discharged). Remedial action Recharge battery. Charging voltage is too low: voltage regulator is defective. Connecting terminals loose or oxidised. Renew the voltage regulator. Battery capacity too low (too many consumers). Clean connecting terminals, apply acidresistant grease, tighten terminal clips.
Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Indication Possible cause Starter does Generator indicator Poor connection (loose lamp is not on. or oxidised), break in not rotate cable or short to earth when (ground). preheat starting switch is opBattery flat or defective. erated. Indicator lamp darkens slowly when preheat-starter switch is operated. Indicator light remains on brightly. Bridge terminals 30 and 50 briefly at the starter.
Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Indication Possible cause Carbon brushes sticking. Starter turns Lengthy period of too slowly or use without mainis unable to tenance or in severe turn the en- conditions. Carbon brushes worn. gine over. Brush springs too weak, Remedial action Renew carbon brushes and brush holder guides. Renew carbon brushes. Renew springs. brushes not making contact. Commutator dirty. Clean commutator.
Troubleshooting chart - electrical system Troubleshooting at the starting equipment Malfunction Starter continues to turn after switch has been released. Indication Noise of starter turning. Engine starts reluctantly or not at all although starter turns quickly. Possible cause Preheat/starting switch does not return automatically from position 2 to position 1. Remedial action Reset the preheat/starting switch to 0 by force if necessary and renew it.
