Hatz Diesel 1D30 S Instruction 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, inclu-
ding 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 trou-
ble shooting information.
Use only GENUINE HATZ PARTS for repairs!
Only these parts guarantee perfect dimensional accuracy and quality.
For the rest, please observe the general legal regulations and the regulations of the re-
sponsible professional associations.
Discrepancies may occur between the described features and actual features owing to
special equipment, and it has not been possible to allow for such discrepancies either in
the Workshop Manual or in the spare parts list.
Should you have any difficulties, please contact your nearest HATZ-Service agent.

1
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
11D . . / 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
1
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
11D . . / 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
1
1D . . / 03.06

11D . . / 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 cm3377 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

1
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 cm3413 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

11D . . / 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 cm3667 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
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
V: vertical crankshaft, non-encapsulated, normal system of balancing,
counter-clockwise rotation
W: vertical crankshaft, non-encapsulated, add. system of balancing,
counter-clockwise rotation

1
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
CO
+
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 cm3Year
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 cm3or 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
11D . . / 03.06

1
1D . . / 03.06
Lubrication oil circuit

11D . . / 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.

1
1D . . / 03.06
Special tools and workshop equipments
2345 6 7
8 9 10 11 12 13 14 15
16 17
19
18
18 19 20 21
22 23 24 25
1

Engine series 1 D . . (SUPRA)
Special tools and workshop equipments
11D . . / 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.