You are on page 1of 76

Workshop manual

2W35
3W35
3W35 T
4W35
4W35 T

Contents
Foreword
1. General
Engine illustrations
Technical data
Type plate data
Jointing material / Sealing and bonding
agents
Special tools and workshop equipments

2. Additional equipments

Contents

3. Basic engine
Replacement of water pump
Replacement of unit injectors
Adjustment of start of delivery
Replacement of camshaft and
timing chain

4. Tables
Injection pump timing and injection pressure
Torque wrench settings
Designations in circuit diagrams
HATZ wiring designations
Electrical circuit diagrams
Sealing plan for crankcase - joint face

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.

1. General

Engine illustrations 2 W 35 3 W 35 4 W 35

17

16

15

14

4
HATZ
RIK TORF
NFABRUHS
TORE099
MO D-94

13

DE
MA

KG

ANY
RM
IN GE

12

11

10

Operators side

1
2
3
4
5
6
7
8
9

Speed adjustment lever


Type plate
Coolant pump
Oil dipstick
Oil filler cap
Drain plug for coolant
Oil drain plug (governor side)
Engine mountings (optional equipment)
Oil drain plug (operators side)

10 Engine oil filter


11 Water drain plug on fuel filter
12 Oil pressure switch
13 Fuel filter with water trap
14 Dry-type air cleaner
15 Combustion air intake port
16 Fuel suction line connector
17 Fuel pre-filter

Engine illustrations 2 W 35 3 W 35 4 W 35

14

15

16

17

13

12

3
4
5
6
7
11

10

Exhaust side

1
2
3
4
5
6
7
8
9

Fuel feed pump


Fuel return line
Stop lever (optional equipment)
Exhaust silencer
Exhaust gas outlet
Electrical starter
Central plug for electrical system
Oil drain plug (exhaust side)
Voltage regulator

10 Fan (optional equipment)


11 Radiator (optional equipment)
12 Coolant supply to engine
13 Coolant return to radiator and thermostat
14 Temperature switch
15 Coolant expansion tank (optional
equipment)
16 Vent line to expansion tank
17 Cylinder head cover

Engine illustrations 3 W 35 T 4 W 35 T (turbocharged engine)

19

18

17

16

4
HATZ
RIK TORF
NFABRUHS
TORE099
MO D-94

15

DE
MA

KG

ANY
RM
IN GE

14

13

12

11

10

Operators side

1
2
3
4
5
6
7

Speed adjustment lever


Type plate
Coolant pump
Oil dipstick
Fan (optional equipment)
Hydraulic pump drive (optional equipment)
Flange for additional hydraulic pump
(optional equipment)
8 Oil drain plug (governor side)
9 Engine mountings (optional equipment)

10 Oil drain plug (operators side)


11 Oil filler cap
12 Engine oil filter
13 Water drain plug on fuel filter
14 Oil pressure switch
15 Fuel filter with water trap
16 Dry-type air cleaner
17 Combustion air intake port
18 Fuel suction line connector
19 Fuel pre-filter

Engine illustrations 3 W 35 T 4 W 35 T (turbocharged engine)

14

15

13

12

11

10

Exhaust side

1 Fuel feed pump


2 Fuel return line
3 Stop lever or stop solenoid
(optional equipment)
4 Turbocharger
5 Exhaust flange
6 Electric starter
7 Oil drain plug (exhaust side)
8 Central plug for electrical system

9 Voltage regulator
10 Coolant supply to engine
11 Coolant return to radiator and thermostat
12 Temperature switch
13 Exhaust manifold
14 Connector for vent line to expansion tank
(coolant)
15 Cylinder head cover

Technical data

Type

2W35

Design

3W35

4W35

3W35T

4W35T

Fluid-cooled four-stroke diesel engine

Combustion air

normal intake

Combustion system

turbo charged

Direct-injection

Number of cylinders

Bore / Stroke

mm

70/90

70/90

70/90

70/90

70/90

Displacement

cm3

692

1038

1384

1038

1384

Lubricating oil capacity

approx. ltr.

2,5 1)

3,4 1)

4,4 1)

3,4 1)

4,4 1)

Difference between
max and min
markings

approx. ltr.

1,2 1)

1,4 1)

1,6 1)

1,4 1)

1,6 1)

Lubricating oil consumption


(after running in)

approx.

0.5 % of fuel consumption


at full load

Lubricating oil pressure


oil temperature 100 C

approx.

3,5 bars at 3000 min-1

Capacity of coolant
(engine only; no radiator,
no external hoses included)

approx. ltr.

2,0

2,5

Direction of rotation
looking at the flywheel

3,0

2,5

counter-clockwise

Tappet clearance at 10 - 30 C
Inlet and exhaust valve

mm

0,10

Max. admissible tilt angle


during operation 2)

max.

25 in all directions

Weight (incl. electric starter, air-cleaner


and exhaust silencer)
without radiator
approx. kg
Battery capacity

1)

2)

3,0

64

76

80

88

92

12V / 55 Ah

These values are intended as an approximate guide. The max. marking on the dipstick is the
determining factor.
Exceeding these limits causes engine breakdown.

Type plate data

115 12 06 001182

3 W 35

Variation (T = Turbo)

MOTORENFABRIK HATZ GMBH


+CO KG
D-94099 RUHSTORF
TYP

KENNZ.

MOTOR / FABRIK NO.

ABE /AUSF.

MIN -1

PV

NH

MADE IN GERMANY

CM 3

1) If required
2) In special cases only; e.g. engines acc. to Federal Authority for Automobilism

Type plate data EPA / Carb

Engine family

Type / Spec./ FDT

6 HZX L.1.38SV 2

3W35

156

-2.0

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)
Engine type

Engine number
115 12 06 001182
Fabrication No.
Year of production
Engine serial No.:
The serial No. beginns
with 10 and changes
continously if any major
changes are carried out
Type No.
Engine speed
2700

330

IMPORTANT ENGINE INFORMATION


+ CO KGD-94099 RUHSTORF
MOTORENFABRIK HATZ GMBH
ENG.FAM.

TYPE / SPEC. / FDT


CM3 / PV

SERIAL NO.
MIN -1

NH / kW

BUILD DATE

Made in Germany
VARIABLE SPEED
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.

Speed increase under


no-load condition
Nominal speed
+380 15.7
Rated power in kW
Injection pump delivery lift
in mm to obtain the required
power output

1038

223

Special adjustment
instruction
Displacement in cm3

Manuf. year
1006
Year
Month

Jointing material / Sealing and bonding agents

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 01

Loctite 574

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

Special tools and workshop equipments


Engine family . W 35

Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

Ident-Nr.
638 871 00
638 872 00
644 735 00
644 309 00
642 716 00
629 223 01
631 392 00
645 879 00
641 061 00
643 476 00
627 500 00
612 087 00
644 335 00
643 649 00
644 327 00
641 063 00
644 775 00
641 068 90
641 050 00
612 090 01
626 383 00
644 308 00
644 374 00
644 315 00
626 753 91
641 397 00
644 342 00
620 926 92
634 142 00
624 838 92
641 610 90
632 913 00
624 863 02
625 682 01
625 751 90
644 365 00
643 962 00
641 060 00

Name
Disassembly tools for cable plug 2,5 mm
Disassembly tools for cable plug 1,5 mm
Adjusting wrench for tappet clearance
Driving device for adjustments
Press-in tool for crankshaft seal ring
Valve lifting tool
Assembly pin for valve stem seal
Controll device for unit injector
Support to crankshaft
Adjusting tool for camshaft
Torx-socket TX 30 1/2"
Dial gauge 1/100 mm
Adjusting tool for start of injection
Fixing pin for speed governor
Socket for start-smoke-limiter
Lever for coil spring to unit injector
Hexagon-socket "2" for unit injector
Fixation plate for cylinder
Punch for closing plug
Piston ring pliers
Piston ring clamping tool 70-100 mm
Tool for syncron gauge crankshaft - camshaft
Manometer for LDA
Adapter for nozzle tester
Impact extractor with accessories
Adjusting gauge for advancer
Fitting device for unit cylinder - cylinderhead
Oil pressure gauge 0 - 6 bar with flexible tube
Honing tool 50 - 175 mm
Rev. meter
Testbox for instrument box
High-pressure pump complete
Elevating table, mobile
Revolvable fixing; basic part
Console for revolvable fixing
Turning device for W35
Lifting device W35
Manometer for leak test

Special tools and workshop equipments

5
+

10

11

19

20

12

13

21

14

15

22

17

16

23

18

24

25

4
5

28

27

26

29

30

31

34

Ma
x.
Tra
gla
Eig
st
en
20
ge
0k
w.
Bj.
g
20
4,5
05
kg
64
39
62
00
.00
02
..
..
.

Ko
st

37
ma

x.

75

0k

35

36
0,4
0,2

0,6
0,8

20

10

30
40

32

33

1,0

38

3. Basic engine

Replacement the water pump

Remove Allen screws.

Pull out Water pump by useing


impact extractor 626 753 91.

Assembly in reverse sequence.


Before carrying out the installation, coat the
flange faces with LOCTITE 5910.

Replacement of unit injectors

Unhook legsprings from rocker using special


tool 641 063 00.

Remove bearing caps for excenter axles.

Open fixing clamps for pump element.

Lift out pump rocker units.

Lock the governor rod with the centering pin


643 649 00 . This is the so called X - position.

Lock the control sleeve in the given position by


tightening the respective screw using special
tool 644 775 00.

To remove valve rockers release lock screw


and unscrew setting nut.
Use special tool 644 735 00.

Remove the valve rockers

Unscrew the fuel lines for forward flow and


back flow.

Remove the choke from the reverse flow connection nipple and unscrew the nipple.

Remove the securing clamps for the fuel pipes,


using a suitable tool.

Using a screwdriver, push the fuel pipes sideways out of the pump nozzle unit.

Release and remove the securing chamber of


the pump nozzle unit.

Suspend the linkage for the regulating sleeve


from the regulating shaft lever.

Draw out the pump nozzle unit or release it with


a suitable impact extractior .

In order to release the pump nozzle on the control side, the fuel return pipe must be removed.
To do this, release the clamp and draw the pipe
out of the connecting element. The remainder
of the dismantling procedure is as described
earlier.
NOTE:
Take care to ensure that no seals remain in the
cylinder head.

Installing the unit injector


NOTE:
In principle, all seals and O-rings are to be replaced.

Hook the connecting rod and draw it up into the


hole in the regulating sleeve.

Place the unit injector in the cylinder head and


press it in as far as the stop.

Place the retaining bar in position and tighten it


slightly (pay attention to the installation position; the radius points towards the pump nozzle).

Use the checking device 645 879 00 to ensure


the radial direction of the pump nozzle is correct.

Tighten the retaining bar with a torque wrench


to 9.5 Nm.

Place the fuel delivery line in position and push


it into the unit injector as far as the stop collar.
In principle, replace the O-rings and apply
some grease in order for them to be fitted more
easily.

After all the unit injectors have been fitted, introduce the delivery lines to a uniform depth
into each unit injector. If this is not done, the individual locking elements cannot be set in
place on top.

Fix the fuel pipes in place with the securing


clamps.

Always replace the sealing rings on the return


line and take care when fitting them that the securing ring is located in the groove.

Push the return line in as far as the stop and


secure it with clamps.

Introduce the fuel pipe into the connection nipple and tighten the nipple.

Subject the fuel system to 5 bar of pressure for


about 2-3 minutes with the high-pressure pump
632 913 00 in order to test the sealing tightness
of the internal fuel lines.

Fit the fuel lines for delivery and return, taking


care in the process to ensure that the choke is
in the correct position in the return line.

Plug the regulator unit into position with the


special tool 643 649 00.

Release the regulator arm.

Suspend the connecting rod into the lowest


hole.

Align the connecting rod at right angles to the


regulating sleeve and the regulating shaft.

Press the connecting rod in the direction unit


injector, in order to compensate for any play in
the moving parts, and secure the regulating
arm.
Repeat the procedure with all the pump nozzle
units.
Take out the alignment pin.

Screw the blocking screw of the regulating


sleeve at the unit injectors as far as the stop.

Fit the rocker arm to the valve control. Adjust


the valve play to 0.10 mm. The valve play is adjusted on the base circle of the camshaft. Adjust the valve play with the adjustment nut and
then fix it with the counter-screw.

Note the correction value of the unit injector. In


this situation, pay particular attention to the
sign + or -. If there is no sign, the value is to be
noted as a - value.

When fitting the rocker arm units to the unit injectors, make sure that the outer units are provided with support for the bearing covers.

Connect the rocker arm and the pump plunger


with the securing clamp.

Lower the rocker arm in the mounting and rotate the eccentric shaft in such a way that the
adjustment hole is pointing upwards.

Place the bearing covers in position in such a


way that the contact surfaces on all bearing
covers point in the same direction. Tighten the
nuts by hand.

Push the rocker arm shaft in the axial direction


until the clamps for the pump piston are located
centrally to the rocker arm and can be moved
without friction resistance.

Apply preliminary tension to the bearing covers


on the side with the contact surfaces as far as
the stop, and tighten the opposite side sufficiently for the shaft still to rotate easily.

Hook the leg spring at the bearing bolt of the


rocker arm into position and apply preliminary
tension with the fitting tool 641 063 00.

Adjusting the start of delivery

Turn the engine over in the direction of rotation


until the roller of the injection rocker arm is located in about the middle of the tangent.

In this position, the scaling of the flywheel is already visible in the viewing hole, which is provided for this cylinder. Now rotate the crankshaft further until the specified setting value coincides with the marking at the viewing hole.

The setting value for the start of delivery is specific to the engine, and is therefore to be taken
from the rating plate or the injection pump setting value table.

+
Set the measuring gauge on the calibration device to a freely chosen pre-tension value. It is
recommended that the gauge be set to three
millimetres, in order to avoid possible contact
between the gauge and engine components.

Carefully place the measuring gauge with the


prism above the roller of the rocker arm and
take care to ensure that the measuring tip is lying in the dome of the cover of the pump nozzle
unit. By applying slight impact movements to
the engine housing, the measuring gauge will
now oscillate to a stable value.

The first aim of the adjustment is to set the


same value in the engine as on the calibration
device (0 position). To do this, rotate the eccentric shaft with a suitable mandrel.

All pump nozzle units are pre-calibrated and


provided with individual correction values. This
value, in hundredths of millimetres, is engraved
on the cover of the pump nozzle unit. The figures express the missing stroke of the pump
piston until the suction hole begins to wear. In
this context, pay particular attention to the sign
+ or -. If there is no sign present, the value is to
be noted as a - value.

By rotating the eccentric shaft further, set the


measuring gauge in accordance with the sign
to the correction value.

Tighten the bearing covers with a torque


wrench.
Tightening torque: 9 + 1 Nm
In this situation, account must be taken of the
fact that the pre-set value will change again.
This needs to be borne in mind when adjusting
the correction value. Deviations in the correction value by +/- five hundredths of a millimetre
are permissible.

Replacement of camshaft and


timing chain

Unhook legsprings from rocker using special


tool 641 063 00.

Remove bearing caps for excenter axles.

Open fixing clamps for pump element.

Lift out pump rocker units.

To remove valve rockers release lock screw


and unscrew setting nut.
Use special tool 644 735 00.

Remove the valve rockers

Remove fuel feed pump.

Remove injection timer shaft.


(additional equipment)

Remove governor spring.

Unscrew the governor unit and draw it out


upwards.

Press out the closure cover.


Rotate the crankshaft to operating top deadcentre of cylinder 1.

Unscrew the cylinder screws from the


camshaft-chain wheel.

Use tongs to draw out upwards the tensioning


pin and the pin for axial securing of the
camshaft.

Secure the chain tightener with the special tool.

Remove the chain wheel and the plastic


toothed wheel from the camshaft.
Draw the camshaft out of the crank casing to
the rear.

Unscrew the Allen screw out of the bearing


flange and remove the flange with an impact
extraction tool.

Remove six Allen screws on the lower chain


wheel.

Remove the axle with an impact extraction tool.

Remove the oil filling device and hydraulic


pump flange respectively.

Press the chain wheel off the gear wheel.

Take out the lower chain wheel.

Draw the upper chain wheel with the control


chain upwards out of the crankcase.

Installation:

Check the flywheel marking:


The engine must be stopped at the upper
dead-centre of cylinder 1!
Locate the gear wheel into the chain drive, in
the correct position in relation to the crankshaft
gear wheel (pay attention to the marking).

Secure the chain drive gear wheel in this


position by fitting the ancillary axle
element ??? ??? ??.

Slide the camshaft into the crankcase, and


locate the plastic gear wheel on the camshaft.

Guide the camshaft chain wheel and the


control chain in from above.

Place the lower chain wheel in position.

Arrange the chain wheels so that they are


pointing towards each other.

Place the lower chain wheel onto the gear


wheel, and tighten the six Allen screws to 9.5
Nm.

Place the upper chain wheel onto the cam


shaft, and tighten the four Allen screws (plus
washer) to 16 Nm.

Remove the ancillary axle element using the


impact extraction tool.
Place the original axle element in place.

Install the bearing flange, and tighten the Allen


screw (with new sealing ring) to 23 Nm.

Insert the securing pin for securing camshaft


axial movement and fix it in position with a tension pin.

Remove the special tool for the chain tightener.

Fit the closure cover so that it is flush with the


crankcase.

Fit the oil filling device and flange to the hydraulic pump respectively.

Fit the governor unit.

Ensure that the adjustment setting elements


are correctly positioned:
Regulator rod in the appropriate lever,
fuel adjustment lever in the slot at the full-load
stop.

Fit the governor spring.

Adjust the governor spring in such a way that it


is in contact with the deflection lever without
any pressure.

Fit the injection timer shaft.

Check for correct seating in the control valve


and in the adjustment cylinder.

Fit the rocker arm to the valve control. Adjust


the valve play to 0.10 mm. The valve play is adjusted on the base circle of the camshaft. Adjust the valve play with the adjustment nut and
then fix it with the counter-screw.

Note the correction value of the unit injector. In


this situation, pay particular attention to the
sign + or -. If there is no sign, the value is to be
noted as a - value.

When fitting the rocker arm units to the unit injectors, make sure that the outer units are provided with support for the bearing covers.

Connect the rocker arm and the pump plunger


with the securing clamp.

Lower the rocker arm in the mounting and rotate the eccentric shaft in such a way that the
adjustment hole is pointing upwards.

Place the bearing covers in position in such a


way that the contact surfaces on all bearing
covers point in the same direction. Tighten the
nuts by hand.

Push the rocker arm shaft in the axial direction


until the clamps for the pump piston are located
centrally to the rocker arm and can be moved
without friction resistance.

Apply preliminary tension to the bearing covers


on the side with the contact surfaces as far as
the stop, and tighten the opposite side sufficiently for the shaft still to rotate easily.

Hook the leg spring at the bearing bolt of the


rocker arm into position and apply preliminary
tension with the fitting tool 641 063 00.

Adjusting the start of delivery

Turn the engine over in the direction of rotation


until the roller of the injection rocker arm is located in about the middle of the tangent.

In this position, the scaling of the flywheel is already visible in the viewing hole, which is provided for this cylinder. Now rotate the crankshaft further until the specified setting value coincides with the marking at the viewing hole.

The setting value for the start of delivery is specific to the engine, and is therefore to be taken
from the rating plate or the injection pump setting value table.

+
Set the measuring gauge on the calibration device to a freely chosen pre-tension value. It is
recommended that the gauge be set to three
millimetres, in order to avoid possible contact
between the gauge and engine components.

Carefully place the measuring gauge with the


prism above the roller of the rocker arm and
take care to ensure that the measuring tip is lying in the dome of the cover of the pump nozzle
unit. By applying slight impact movements to
the engine housing, the measuring gauge will
now oscillate to a stable value.

The first aim of the adjustment is to set the


same value in the engine as on the calibration
device (0 position). To do this, rotate the eccentric shaft with a suitable mandrel.

All pump nozzle units are pre-calibrated and


provided with individual correction values. This
value, in hundredths of millimetres, is engraved
on the cover of the pump nozzle unit. The figures express the missing stroke of the pump
piston until the suction hole begins to wear. In
this context, pay particular attention to the sign
+ or -. If there is no sign present, the value is to
be noted as a - value.

By rotating the eccentric shaft further, set the


measuring gauge in accordance with the sign
to the correction value.

Tighten the bearing covers with a torque


wrench.
Tightening torque: 9 + 1 Nm
In this situation, account must be taken of the
fact that the pre-set value will change again.
This needs to be borne in mind when adjusting
the correction value. Deviations in the correction value by +/- five hundredths of a millimetre
are permissible.

4. Tables

Injection pump timing and injection pressure

Begin of delivery:
2 / 3 / 4 W35 (T) without timing device
2 / 3 / 4 W35 (T) equipped with timing device

7 [9] b TDC *)
-2 [0] b TDC *)

*)Value set between brackets [ ] are valid for assembly of new engines
or after renewal of chaindrive!
Injection pressure:
(after a running period of approx. 100 hours)

250 + 12 bar
3600 + 110 psi

Torque wrench settings


General [Nm]:
Nm 9.81(10) = kpm
Nm 1.3558 = Lbs 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

M10

29

46

65

78

M12

50

80

110

140

M14

80

130

180

220

M16

120

190

270

330

M18

170

270

380

450

M20

240

380

530

640

M22

320

510

720

860

Torque wrench settings


Nm

lbs ft

Nm

lbs ft

3.5+0.5 2.6+0.4

9.51

70.75

21.41 15.80.75

655

483.7

161 11.80.75

5+1

3.7+0.75

273

202.2

182

13.31.5

13515 10011

9+1

6.6+0.75

Code designations in circuit diagrams (DIN 40719)


Code

Designation of electrical component

A1
A2
A3
A4

Equipment box
Equipment panel
Automatic start-stop
Starter protection module

B1
B2
B3
B4

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

H1
H2
H3
H4
H5
H6
H7
H8

Indicator lamp, generator telltale


Indicator lamp, oil pressure
Indicator lamp, engine temperature
Indicator lamp, air cleaner (maintenance switch)
Indicator lamp, broken belt
Indicator lamp, preheat monitor
Indicator lamp, fan monitor
Remote display: engine on

K1
K2
K3
K4
K5
K6
K7
K8

Control relay 1 for start / start repeat interlock


Control relay 2 for preheat
Control relay 3 fr speed control
Engine protection relay
Delay relay
Start interlock relay
Timer relay (impulse relay)
Power relay

M1
MG

Starter motor
Starter-generator

N1
N2
N3
N4

Regulator for starter-generator


Regulator for flywheel generator
Regulator for alternator (unless integrated)
Pulse sensor (additional for syncro-regulator)

Code designations in circuit diagrams (DIN 40719)


Code

Designation of electrical component

P1
P2
P3

Operating hours counter


Revolution counter
Pressure display

R1
R2
R3
R4
R5

Preheat glowplug
Heating flange
Line resistor for preheat system
Resistor
Line resistor with thermal time switch

S1
S2
S3
S4
S5
S6
S7
S8
S9
S 10
S 11
S 12

Preheat starter switch (5 positions)


Master switch
Preheat starter switch (3 positions)
Start-stop switch
Speed control switch
Engine temperature switch
Oil pressure switch
Pressure switch for air cleaner
Fan monitoring switch
Preheat temperature switch
Remote start switch
Remote stop switch

T1

Engine speed measurement transmitter

V1
V2
V3
V4

Decoupling diode
Freewheeling diode
Zener diode
Suppressor diode

W1
W2

Earth (ground), negative return line


Screened line at generator

X1
X2
X3
X4
X5

Terminal strip on equipment box


Flat-plug distributor
Plug at emergency stop switch
Socket on emergency stop switch
Terminal block on control box / terminal box

Y1
Y2
Y3
Y4
Y5

Speed control actuating solenoid


Engine shutdown actuating solenoid
Servo solenoid (= valve solenoid) for engine shutdown
Fuel shutoff valve
High-pressure shutdown valve

Z1
Z2

Suppressor choke
Suppressor capacitor

HATZ wiring designations


Terminal
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Designation
Earth (ground)
Generator B+
With alternator: D+
With flywheel generator: Terminal L at regulator
Starter terminal 50
Oil pressure switch
Temperature switch on cylinder head
Preheat glowplug I
Engine shutdown solenoid
Preheat glowplug II
Start-stop input
Positive terminal for DC motor, precision speed control
Negative terminal for DC motor, precision speed control
Oil pressure sensor
* * * reserved for special applications * * *
Speed control solenoid - holding-on winding
* * * reserved for special applications * * *
Actuating solenoid for decompressor
Maintenance switch for air cleaner
Engine shutdown solenoid (energising winding)
Temperature sensor at cylinder head
Oil temperature switch
Fan monitoring switch
Terminal W for engine-speed measurement
Starter 30 (with ammeter connection)
Terminal C with regulator on flywheel generator
Oil temperature sensor
Terminal 50f at starter protection module
* * * reserved * * *
Speed control solenoid (energising winding)
* * * reserved * * *

Code marking with electrical wires


Pin connector on wiring harness

"X"

"X"

Socket connector on engine

"Y"

"Y"

1
2
A
B
C
D
E
F
G
H
J
K
L
M
N

Power supply B+ (1)


Starter motor 50 (3)
Charging lamp (2)
Oil pressure switch (4)
Temperature switch (5)
reserved
Engine shutdown solenoid (7)
reserved
reserved
Maintenance switch for air cleaner (17)
reserved
reserved
Terminal C with regulator on flywheel generator (24)
Power supply customer (24)
Ground (0)

X1

30

C
L
U
B+
G/~ G/~ W

012

15

31

M1

30

45

H1 H0

Starting device

H24 H0

15

22 24 1 2 3

G1

50a

Power supply / Charging device

G3

N2

S1

50

PU

S8

S7

S6

3
AW
Y2

Engine

7
HW

18 7

H7

Instrument box

Monitoring + Display Engine shut-down

17 4 5

H2 H17 H4 H5

A5

START

Circuit diagram - Instrument box with display and flywheel alternator

X1

30

C
L
U
B+
G/~ G/~ W

012

15

31

M1

30

45

Starting device

H24 H0

15 50

22 24 1 2 3

G1

50a

Power supply / Charging device

G3

N2

S1

50

PU

S8

S7

S6

3
AW
Y2

Engine

7
HW

18 7

H7

Instrument box

R1

13

H6

Monitoring + Display Engine shut-down Preheating

17 4 5

H2 H17 H4 H5

A5

START

Circuit diagram - Instrument box with autom. pre-heat / shut down system and flywheel alternator

012

B+

X1

30

50a

G1
31

M1

30

45

H1 H0

Starting device

H24 H0

15

22 24 1 2 3

15

Power supply / Charging device

3~

G2

S1

50

PU

S8

S7

S6

3
AW
Y2

Engine

7
HW

18 7

H7

Instrument box

Monitoring + Display Engine shut-down

17 4 5

H2 H17 H4 H5

A5

START

Circuit diagram - Instrument box with display and three-phase alternator

012

B+

X1

30

50a

G1
31

M1

30

45

Starting device

H24 H0

15 50

22 24 1 2 3

15

Power supply / Charging device

3~

G2

S1

50

PU

S8

S7

S6

3
AW
Y2

Engine

7
HW

18 7

H7

Instrument box

R1

13

H6

Monitoring + Display Engine shut-down Preheating

17 4 5

H2 H17 H4 H5

A5

START

Circuit diagram - Instrument box with autom. pre-heat / shut down system and three-phase alternator

Display settings
DV 40 - 90

7.3 Learn curve Diesel (only DV 40)


-

Start engine, confirm shunt mode with Y Enter, to open the operational mode.
Warm up the engine. The idle-running speed must be 1200 min-1 and the engine has
to run in a smooth way (constant number of revolutions no up and down => otherwise HATZ-Service).

Press R System, select the menu item Service with U up or V down and
confirm with Y Enter.

Select the submenu Learn curve Diesel with U up or V down and confirm with

Y Enter.

Shunt mode

Operational mode

System page

Service page

After confirmation, enter the password.

HAMM AG
Version 032.000 26/01/2005

29/63

HAMM Id.-Nr.: 204 27 57

Display settings
DV 40 - 90

7. Display settings

7.1.1 Password entry


- You will receive the required password by
telephone with the HAMM Service
Department.
- Upon your call, please keep the 8-digit
number next to the telephone icon ready.
- Enter the 8-digit password via the
keyboard of the display.
- After the correct entry of the password, the
desired menu will be displayed.
- The validity of the password is temporary!

HAMM AG
Version 032.000 26/01/2005

21/63

HAMM Id.-Nr.: 204 27 57

Display settings
DV 40 - 90
1. First of all disconnect the carburet throttle controls from the
servo motor (SM).
2. Then move the SM to its lower

1000 1/min

stop position by pressing X.

960
3436

3. Adjusting the length of the


carburet throttle control:
Move the carburet throttle controls to the lower stop (HATZ).
The carburet must be approximately 1/2 ball shaped head
shorter (compared to the ball
mounted at the SM).

4. Move the SM to Position up by


pressing V.

5. Move the carburet throttle control


(HATZ) to the full-load stop
manually to check the carburet
length. The carburet should now
protrude the ball mounted on the
SM about ball shaped head.
6. Now move the SM to Position
middle by pressing W. Fit the
carburet to the SM and secure
it.

HAMM AG
Version 032.000 26/01/2005

30/63

HAMM Id.-Nr.: 204 27 57

Display settings
DV 40 - 90
7. The result shown in the picture
on the right must be achieved.
Possibilities for adjustments:

HATZ throttle lever (only if


necessary)
upper ball shaped head
lower ball shaped head

8. Finally start the learn curve by pressing Y Enter

Terminate calibration with Y Enter

Procedure: learn curve is active!

- Exit the system page with R System, to


return to the operational mode.
- Check Diesel speed in the display : Idle
running speed is 1200 rpm
- To carry out a reset and therefore a data
backup, switch the ignition OFF and
ON.

HAMM AG
Version 032.000 26/01/2005

31/63

HAMM Id.-Nr.: 204 27 57