Hatz Diesel 1D50 S, 1D60 S, 1D80 S, 1D81 S, 1D90 S Workshop Manual

...

Workshop manual

438 202 01 - Printed in Germany

1 D . .

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 Fuel

A 01.10 Fuel tank A 01.40 Fuel feed pumps

A 02:00 Combustion air

A 02.10 Oil bath air filters A 02.11 Dry type air filters A 02.13 Service indicators;

vacuum gauges

A 02.20 Pre-cleaners; cyclons

A 03.00 Exhausts

A 03.12 Exhaust-silencers,

Protection guard

A 04.00 Start mechanical

A 04.10 Starting handles

without supports A 04.11 Starting handle supports A 04.12 Cranking claws A 04.30 Rope starts

A 05.00 Start electrical

A 05.20 Starter motors A 05.40 Alternator / Magnet segments A 05.41 Alternator / Coils A 05.80 Ring gears

A 07.00 Lubrication oil

A 07.20 Lub.-oil filters, strainers A 07.30 Oil sumps

A 09.00 Speed controls

A 09.60 Low idle speed stabilization

A 11.00 Remote engine controls

A 11.10 Stop devices A 11.30 Auto. Shut-off device

A 15.00 Housings, flanges,

adaptors

A 15.20 Adaptor housings

Contents

3. Basic engine

M–Disassembly cross reference scheme M 01.00 Crankcase

M 01.10 Crankcase, nozzle

and bearings M 01.11 Plugs M 01.20 Crankshaft-thrustplate

and cam followers M 01.30 Oil sump and suction sieve M 01.31 Oil sump 1 D 50 M 01.40 Base plate and

oil pressure relief valve M 01.50 Cyl.-head screw sealants

M 02.00 Crankshaft

M 02.10 Wear and grinding dimensions M 02.20 Crankshaft gearwheel and

stubshafts M 02.30 Crankshaft / Wear sleeve

M 03.00 Bearing flange

M 03.10 Bearing flange 1D 90 V/W

M 04.00 Camshaft and balancer unit M 05.00 Piston with connecting rod

M 05.10 Piston and piston rings M 05.20 Connecting rod

M 06.00 Cylinder M 07.00 Cylinder head

M 07.10 Rockers and decompression

device M 07.20 Bumping clearance M 07.30 Cyl.-head and oil supply pipe M 07.40 Valves, valve guides and

valve seats

M 08.00 Cover for cylinder head M 09.00 Pushrods / Protection tubes M 10.00 Oil pump / Governor M 11.00 Timing cover M 12.00 Extra fuel device M 14.00 Fuel-injection equipment

M 14.10 Fuel pressure pipe M 14.20 Injector M 14.30 Injection pump M 14.40 Roller tappet

M 17.00 Flywheel M 26.00 Cowling / Air duct M 31.00 Breather system M 32.00 Speed control M 35.00 Capsule

4. Data sheets

Injection equipment adjustment data Governor equipment General adjustment and testing data Screw tightening torques Designations in circuit diagrams HATZ wiring designations Electrical circuit diagrams Circuit diagram for measuring currents and voltages Generator output characteristic Troubleshooting – electrical system

Contents

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. since it is assumed, of course, that the mechanic will be aware of the necessity of carrying out such work.

Use only the tools prescribed or absolutely identical tools when carrying out work of whatever nature.

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

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

Use only GENUINE HATZ PARTS for repairs! Only these parts guarantee perfect dimensional accuracy and quality.

For the rest, please observe the general legal regulations and the regulations of the responsible professional associations.

Discrepancies may occur between the described features and actual features owing to special equipment, and it has not been possible to allow for such discrepancies either in the Workshop Manual or in the spare parts list.

Should you have any difficulties, please contact your nearest HATZ-Service agent.

1D . . / 03.06

1. General

1 Cooling air inlet 2 Oil pressure switch 3 Dry type air cleaner 4 Decompression lever 5 Cooling air outlet 6 Extra fuel device 7 Injection pump 8 Injector

9 Cylinder head cover 10 Cold start-oil priming device 11 Lifting bracket, max. 120 kg / 265 lb 12 Fuel filler cap 13 Stop lever 14 Timing cover 15 Guiding shell for starting handle 16 Fuel pressure pipe 17 Governor

1D . . / 03.06

18 Flywheel 19 Engine flange 20 Fuel tank 21 Engine base plate 22 Exhaust silencer 23 Fuel feed pump (mounting pos.) 24 Oil drain plug, governor side 25 Injection pump bleeder valve 26 Speed control lever 27 Oil drain plug, control side 28 Oil pressure relief valve 29 Oil filling hole and dipstick 30 Fuel filter 31 Oil filter (optional) 32 Type plate 33 Fuel tank drain plug 34 Combustion air intake

Engine illustrations

Engine 1D30, 1D31, 1D40, 1D41, 1D50, 1D60, 1D80, 1D81, 1D90 S/Z/T/U

16 Speed control lever 17 Oil filling hole and dipstick 18 Engine base plate 19 Oil drain plug, control side 20 Type plate 21 Engine flange 22 Cooling air outlet 23 Timing cover 24 Governor 25 Oil drain plug, governor side 26 Injection pump 27 Oil pressure relief valve 28 Fuel pressure pipe 29 Cooling air inlet 30 Flywheel 31 Combustion air intake

1D . . / 03.06

1 Air filter 2 Oil pressure switch 3 Injection pump bleeder valve 4 Extra fuel device 5 Air cowling cover 6 Exhaust silencer 7 Fuel tank 8 Fuel filler cap

9 Lifting bracket, max. 120 kg / 265 lb 10 Cold start-oil priming device 11 Decompression lever 12 Fuel tank drain plug 13 Oil filter (optional) 14 Fuel filter 15 Fuel feed pump (mounting pos.)

Engine illustrations

Noise-optimized version Engine A1D35, A1D40, A1D41 S/Z/T/U

1 Capsule 2 Decompression lever 3 Cold start-oil priming device 4 Combustion and cooling air intake 5 Oil filter 6 Cleaning opening 7 Side panels 8 Access for starting handle

9 Lifting bracket, max. 120 kg / 265 lb 10 Exhaust silencer, enclosed 11 Engine flange

1D . . / 03.06

12 Flywheel 13 Cooling air outlet 14 Battery connections and central plug

for electrical system 15 Access to timing cover 16 Stop lever 17 Speed control lever 18 Oil drain plug 19 Oil filling hole and dipstick 20 Type plate

Engine illustrations

Fully encapsulated version Engine 1D30C, 1D31C, 1D40C, 1D41C, 1D60C, 1D80C, 1D81C

1 oil filler cap 2 dipstick 3 type plate 4 combustion air intake 5 dry type airfilter 6 fuel tank drain plug 7 cylinder head cover 8 fuel filler cap 9 cooling air inlet

10 mechanical maintenance indicator

11 speed control lever 12 oil filter 13 fuel filter 14 cooling air outle 15 decompression levert 16 exhaust silencer 17 electric starter 18 central plug f. electrical equipment 19 oil drain plug

Engine illustrations

Engine 1D90 V/W

1D . . / 03.06

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 1 1 1

Bore / stroke mm 86/65 86/65 86/65

Cubic capacity cm

377 377 377

Compression ratio 1D30: 20.5:1 20.5:1 20.5:1

1D31: 21.0:1 22.0:1*

Direction of rotation 1D . . S / Z / C counter-clockwise looking at the flywheel 1D . . T / U clockwise

Cooling air required at 3000 min

-1

m3/min 6.0 6.0 6.0

Combustion air required at 3000 min-1 m3/min 0.56 0.56 0.56

Oil capacity without oil filter approx. 1.1 1.1 1.1

with oil filter ltr. 1.2 1.2 1.2

Difference between approx. 0.4 0.4 0.4 „max“ and „min“ markings ltr.

Oil consumption Approx. 1% of fuel combustion at full load

Max. permissible inclination approx. 30° approx. 30° approx. 30° in each direction during operation

Net weight Engine models S, Z, T, U approx. 68 68 74 Engine models C kg 89 89 –

Model S: non-encapsulated, normal system of balancing, counter-clockwise rotation

Z: non-encapsulated, add. system of balancing, counter-clockwise rotation T: non-encapsulated, normal system of balancing, clockwise rotation U: non-encapsulated, add. system of balancing, clockwise rotation C: SILENT PACK, add. system of balancing, counter-clockwise rotation

*Engines in connection with compaction units

Technical data

1D . . / 03.06

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 1 1 1

Bore / stroke mm 90/65 97/70 88/85

Cubic capacity cm

413 517 517

Compression ratio 20.0:1 20.0:1 20.5:1

Direction of rotation 1D . . S / Z / C counter-clockwise looking at the flywheel 1D . . T / U clockwise

Cooling air required at 3000 min-1 m3/min 6.0 6.0 10.5

Combustion air required at 3000 min-1 m3/min 0.62 0.78 0.78

Oil capacity without oil filter approx. 1.1 1.4 1.8

with oil filter ltr. 1.2 1.5 1.9

Difference between approx. „max“ and „min“ markings ltr. 0.4 0.5 0.9

Oil consumption Approx. 1% of fuel combustion at full load

Max. permissible inclination in each direction during operation approx. 30° approx. 30° approx. 30°

Net weight Engine models S, Z, T, U approx. 68* 76 91 Engine models C kg 89 – 114

Model S: non-encapsulated,normal system of balancing,counter-clockwise rotation

Z: non-encapsulated, add. system of balancing, counter-clockwise rotation T: non-encapsulated, normal system of balancing,clockwise rotation U: non-encapsulated,add. system of balancing, clockwise rotation C: SILENT PACK, add. system of balancing, counter-clockwise rotation

*A1D41: 74 kg

Technical data

1D . . / 03.06

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 1 1

Bore / stroke mm 100/85 104/85

Cubic capacity cm

667 722

Compression ratio 20.5:1 20.5:1

Direction of rotation 1D . . S / Z / C / V / W counter-clockwise looking at the flywheel 1D . . T / U clockwise

Cooling air required at 3000 min-1 m3/min 10.5 10.5

Combustion air required at 3000 min-1 m3/min 1.0 1.1

Oil capacity without oil filter approx. 1.8 1.8

with oil filter ltr. 1.9 1.9

Difference between approx. „max“ and „min“ markings ltr. 0.9 0.9

Oil consumption Approx. 1% of fuel combustion at full load

Max. permissible inclination in each direction during operation approx. 30° approx. 30°

Net weight Engine models S/Z/T/U/V/W approx. 91 92 Engine models C 121 –

Model S: non-encapsulated, normal system of balancing, counter-clockwise rotation

counter-clockwise rotation

W: vertical crankshaft, non-encapsulated, add. system of balancing,

counter-clockwise rotation

1D . . / 03.06

Type plate data

EPA / Carb type plate data

ENG.FAM.

TYPE / SPEC. / FDT

MIN

SERIAL NO.

NH / kW

-1

MOTORENFABRIK HATZ KG·D-94099 RUHSTORF

CM3 / PV

BUILD DATE

IMPORTANT ENGINE INFORMATION

This engine conforms to MY U.S. EPA regulations large nonroad compression-ignition engines and MY California

regulation for off-road compression-ignition engines.

Refer to owner's manual

for maintenance specifications and adjustments.

VARIABLE SPEED

GMBH

Made in Germany

0.98 10.4 0667 189A

0504

1D81 Z 216B 13.04 HZX L.667 V 83

2950 290

073 23 04 083019

Rated power in kW Injection pump delivery lift in mm to obtain the required power output

Special adjustment instruction

Displacement in cm

Year

Month

Variation

Customer specification (only for special equipment)

Engine type

Static timing (begin of fuel delivery)

V = variable speed application C = constant speed application A = V + C as well

Displacement (in cm

or liters)

Diesel engine (Benzin/gasoline = S)

Manufactorer HZX = HATZ

Manuf. year (X = 1999, Y = 2000, 1 = 2001,...)

Type code

Speed increase under no-load condition

Nominal speed

Engine serial No.: The serial No. beginns with 10 and changes continously if any major changes are carried out

Year of production

Type No.

Fabrication No.

Manuf. year

Type / Spec./ FDTEngine family

Engine speed

Engine number

1D . . / 03.06

Lubrication oil circuit

1D . . / 03.06

Special tools and workshop equipments

Engine series 1 D . . (SUPRA)

Bezeichnung

Verwendung

bei Typen

30-50 60-90

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

644 345 90 630 815 00 629 301 00 629 102 00 627 501 00 632 579 00 629 223 01 631 392 00 603 823 91 629 016 02 629 298 02 627 496 02 627 398 02 629 299 02 629 284 00 627 494 00 634 147 00 627 495 02 627 500 00 631 133 01 665 030 91 625 401 90 612 087 00 612 090 01 626 383 00 639 477 00 636 421 00 640 564 00 626 753 91

Clip tool for lead plugs Allen socket 6 mm lg 1/2" Clamp for pushrod tube Clamp for pushrod tube Retainer for governor spring Adjustment wrench Valve lifter Mandrel for valve stem seal cap Multi-purpose extractor Punch for main bearing gov.-side Punch for main bearing gov.-side Punch for outer camshaft bushing Punch for main bearing flywheel side Punch for main bearing flywheel side Heating insert for gear/stubshaft Drift punch for camshaft bushing Comb. extractor f. gear + stubshaft Assembly device for oil pump shaft Torx-socket TX 30 – 1/2" Ring spanner 18 x 19 for starter Spill device for injection pump M18x1.5 Spill device for injection pump M20x1.5 Dial gauge – 1/100 mm Piston ring pliers Piston ring clamp.device ∅ 70-100 mm Measuring device for injection pump Pliers for EPA - radial (tamper-resistant) Pliers for EPA - axial (tamper-resistant) Impact hammer with fittings

xx xx x– –x xx xx xx xx xx –x x– xx –x x– xx xx xx xx xx xx xx xx xx xx xx xx xx xx xx

Ident-Nr.Nr.

1D . . / 03.06

Special tools and workshop equipments

345 6 7

8 9 10 11 12 13 14 15

16 17

1 9

18 19 20 21

22 23 24 25

Engine series 1 D . . (SUPRA)

Special tools and workshop equipments

1D . . / 03.06

Nr.

Bezeichnung

Verwendung

bei Typen

30-50 60-90

26 27 28 29 30 31 32 33 34 35 36 37 38 39

633 013 00 620 926 92 630 094 90 634 142 00 624 838 92 641 610 90 633 178 00 632 913 00 624 863 02 625 682 01 625 751 90 631 300 00 644 991 01 645 020 00

Forcing screw for centrif.-clutch Oil pressure gauge 0... 6 bar Test nozzle 400 bar / 5800 psi Honing tool Rev.-counter for fuel press.-pipe Testbox for instrument box Components testbox High-pressure supply pump Hydraulic lift trolley Revolvable fixing - basic part Console for revolvable fixing Revolvable fixing - adaptor engine side Socket wrench for lock nut Punch for tab washer

xx xx xx xx xx xx xx xx xx xx xx xx xx xx

Ident-Nr.

1D . . / 03.06

Special tools and workshop equipments

15 86

87a

STAR

- +

max. 750 kg

1D . . / 03.06

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. See the following list for decoding the material; this list is the same as already being used with all other service literature including spare parts list.

A = 502 230 01 Loctite Activator 500 ml B = 502 231 00 Loctite 573 50 ml C = 502 232 00 Loctite 601 50 ml D = 502 233 00 Loctite 221 50 ml E = 502 234 00 Loctite 648 10 ml F = 502 238 00 Technicoll 8058 750 g

+ 502 239 00 Technicoll 8367 750 g G = 502 565 01 Loctite IS 407 20 g H = 502 825 01 Silicon sealer 30 ml J = 502 830 02 Anti-Seize compound 1000 g K = 503 426 00 High-temp. lub.-grease 100 g L = 502 566 00 Silicon sealer 100 g M = 504 851 00 Polishing paste K 240 80 ml

1D . . / 03.06

2. Additional equipment

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 compo-

nents if necessary.

Inspection / repair:

– Visual inspection. – Check fuel tank for cracks and/or any

other damage. – Check all rubber parts for ageing etc. Maintenance according to instruction book!

Assembly:

– Re-assemble and re-connect fuel tank 4

and fuel filter 5 as well as fuel hoses 2...3.

Tighten all retaining items uniformly to

obtain a stress free assembly of the fuel

tank. – Remove clamp tool and/or tighten drain

plug 1.

1D . . / 03.06

A 01.00 Fuel

A 01.00

A 01.10

1D . . / 03.06

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. If turning of the stud cannot be avoided, remove the spring from the pin. The front cover must be removed to remove the spring. Ref.: Chapt. M 11.00

Inspection / repair:

– Visual inspection. For further repair proceed as follows: – Remove in numerical sequence 5 ... 14. Required only if irregularities such as poor suction / pumping action i.e. contaminated strainer or leaks have been noted. – Check and replace all parts in question.

Assembly:

– Pre-assemble in reverse sequence 14...5. – Assemble in reverse sequence 3 ... 1. – Ensure actuating lever 16 is in bottom

position and „O“-Ring 3 remains in its

groove when assembling. – After installation and a short test run,

check the fuel system for leaks.

II. Fuel feed pump drive General: Models Z/U/C

Bushing 15 is replaced by the actuating lever 16.

Models S/T

Plug 17 is replaced by the plug 18 with ring groove.

Preparations:

– Remove fuel feed pump. – Remove timing cover.

Ref.: Chapt. M 11.00

Dismantling:

– Remove part 20/21 and lever 16. – Remove shaft 19.

For removal use tool - 25 - Plug 18 remains in crankcase.

Inspection / repair:

– Visual inspection. – Check parts for wear and/or any other

damage.

Assembly:

– Assemble in reverse sequence . – Press in shaft 19 to a protrusion of 52 ±

0,5 mm. Extractor thread must face front!Models

Z/U/C

Ensure all gear timing marks match!

– Finish assembling.

A 01.00 Fuel

1D . . / 03.06

A 01.00

A 01.40

1D . . / 03.06

A 02.10 Oil bath air filters

–

General:

The oil bath air filter is fitted by means of an intermediate flange which adapts from the triangle-type flange at cylinder head to the twin-screw flange of oil bath air filter. This flange also holds the glow plug in case a pre-heating system is fitted.

Preparations: – Dismantling:

– Disconnect cable connection from glow

plug if fitted. – Remove in numerical sequence 1...9.

Studs and Hex.-head screw plug or glow

plug may remain.

Don't tip oil bath air filter !

Inspection / repair:

– Visual inspection. – Check air filter body for cracks and/or any

other damage. Maintenance according to instruction book! NOTE: Never „repair“ an oil bath air filter by welding/soldering etc. It causes total damage to the part and may lead to engine failure!

Assembly:

– Assemble in reverse sequence 9...1.

Ensure the correct amount of gaskets are used and parts seal properly to avoid infiltrated air. When fixing the oil bath air filter take care for correct position of kidneyshaped washers 3, convex side faces retaining nuts 1.

– Reconnect cable connection to glow

plug if so fitted.

A 02.00 Combustion air

1D . . / 03.06

A 02.00

A 02.10

A 02.11 Dry type air filters

–

Version A 02.11.1

Fixation of filter element and cover by flat washers and Hex.-nuts.

Preparations: – Dismantling: – Remove in numerical sequence 1...10.

Inspection/repair:

– Visual inspection. – Check filter element 6 and sealing strip

around cover 3. Maintenance according to instruction book!

Assembly:

– Assemble in reverse sequence 10...1.

Torque to specification! NOTE: Mind total length of bushing 4 and washer 5 respectively length of bushing 4 without washer. Take care for correct position of insulating flange in between, correct amount of gaskets and proper sealing of all parts to avoid infiltrated air.

Conversion:

Possible to current standard in case all parts in question become replaced.

1D . . / 03.06

Version A 02.11.2

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...12. – If necessary dismantle cover retaining

screw to replace sealing sleeve (rubber)

between screw cap and cover.

Inspection / repair:

– Visual inspection. – Check filter element 6 and sealing strip

around cover 1. Maintenance according to instruction book!

Assembly:

– Assemble in reverse sequence 12...1.

Torque to specification! NOTE: Take care for correct position of insulating flange in between, correct amount of gaskets and proper sealing of all parts to avoid infiltrated air. – Reconnect cable connection to heater

flange if so fitted.

Conversion:

Possible to current standard in case all parts in question become replaced.

A 02.00 Combustion air

+ 163 hidden pages

Hatz Diesel 1D50 S, 1D60 S, 1D80 S, 1D81 S, 1D90 S Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual