Training

Messrs. Wacker
Sept. 2006
INDEX
1 Hatz engine range – families – types – versions – variants

2 Type plate data

3 Operation and maintenance

4 Technical features and adjustments in general

5 Function of components, adjustments and repairs 1 B..*

6 Function of components, adjustments and repairs 1 D..*

7 Electrics

* electric systems, developed, installed and wired by HATZ

09.2006 – VMS-kre-es
 1

Hatz –
the engine range
List of engine families, types and versions

Range Bore x
and Basic types stroke Typ- Versions Remark and explanation of code letters
No.
colour (mm)
1 B 20 69 x 62 100 P.t.o.shaft, integral with crankshaft:
1 B 30 80 x 69 101 .1 = cylindr. SAE 1” with outside thread
B.. -1
1 B 40* 88 x 76 110 .2 = cylindr. SAE 1” with key way
1 B 50* 93 x 76 124 -2 .3 = tapered
apple -4
green 1 B 20 V 69 x 62 111 .4 = tapered SAE “Gen.”
1 B 30 V 80 x 69 112 -6 .5 = cylindr. with outside thread
-7 .6 = tapered Ital. 23 mm
1 B 40 V 88 x 76 117
-8 .7 = cylindr. SAE 3/4” with key way
1 B 50 V 93 x 76 126 -x
.8 = cylindr. SAE 3/4” with outside thread
1 B 27 79 x 62 125 .9 = cylindr. metric with key way
1 B 20 NON-EPA 69 x 62 300 ...V-
1 B 20 V 69 x 62 301 Semi-machined shaft SW 27 / SW 32 for special applications
1 B 30 80 x 69 302 *..T
1 B 30 V 80 x 69 303 *..U .x = short crankshaft, to screw in stubshaft or any other p.t.o.
1 B 40* 88 x 76 304 component
1 B 40 V 88 x 76 305 ..V = horizontal position with vertical crankshaft
1 B 50* 93 x 76 306
1 B 50 V 93 x 76 307 ..T = clockwise rotation without balance shaft
1 B 27 74 x 62 308 ..U = clockwise rotation with balance shaft

E 571... 71 x 57 30 )..LN(F)* E … ... = Singe cylinder

5/6 * E 671... 71 x 67 29 )..RN(F)* . … L.. = anti-clockwise rotation
E 572... 71 x 57 45 )..LK(F)* . … R.. = clockwise rotation
blue E 672... 71 x 67 46 )..RK(F)* . … .N = protruding camshaft*
E 573... 73 x 67 57 )..LHK* . … .K = protruding crankshaft*
E 673.. 73 x 67 56 )..RHK* . … ..F = flangeable at governor side*
)..LS . … .HK = add. handstart gear (previous version for crankhandle) start*
HE 673.. 73 x 67 58 )..LR* . … LS = short version for handcrank start and up-to-date (short
(BMW-D 7) )..L36 version (anti-clockwise only)
)..R36 . … LR = Recoil start (anti- .3. = ital. flange*
)..L3N clockwise only) .4. = Flange SAE A
)..R47 H. … .. = watercooled ..6. = ital. stubshaft*
* = for p.t.o. gov. side ..7. = Stubshaft cyl. SAE 3/4”
..N*= Tapered camshaft end

7..* E 71 71/75x80 23 ) .E = Singe cyl., power-take-off on flywheel as well as on gov. end

E 75 75 x 80 16 ) .ES = Power-take-off on flywheel side only; crankshaft not
yellow E 79 82 x 80 24 ) E.. protruding on gov. end
E 780. 82 x 100 27 ) ES.. . … U = Counter-rotating balance weight installed
E 785. 85 x 110 28 )
E 786. 85 x 110 77 )
E 780 U )
E 785 U ) no “ES”-versions
E 786 U )
HE 780 (U)
(BMW=D12) 82 x 100 59 ) H. … = watercooled

1 D 20 * 87 ) ) A.. = semi-capsuled*
D.. 1 D 30..* 86 x 65 92 ) ) ..S = anti-clockwise rotation, uncapsuled, no counter balance shafts
1 D 31.. 86 x 65 71 ) ) T = clockwise rotation, uncapsuled, no counter balance shafts
pink A 1 D 35..* 86 x 65 93 )..S ) ..Z = anti-clockwise rotation, uncapsuled with counter balance shafts
1 D 40..* 86 x 65 88 )..T )2. ..U = clockwise rotation, uncapsuled with counter balance shafts
A 1 D 40..* 86 x 65 62 )..Z )3. .C = anti-clockwise rotation, capsuled with counter balance shafts
1 D 41.. 90 x 65 94 )..U ) .2 (only 1 D 30-31-41-60-80-81)
A 1 D 41..* 90 x 65 95 )..C ) .3 ..V. = horizontal position with vertical crankshaft, no counter balance
1 D 50 97 x 70 109 ) ) .4 shafts, with 1D90 only
1 D 60.. 88 x 85 89 ) ) .6 X = - ditto - clockwise rotation
1 D 80..* 100 x 85 90 ) ) ..W. = vertical (vertical crankshaft), anti-clockwise rotation,
1 D 81.. 100 x 85 73 ) ) with counter balance shafts;
1 D 90.. 104 x 85 108 ) ) with 1D90 only
Y = - ditto - clockwise rotation
1 D 90 104 x 85 113 ..V.
..W. Flange gov. side p.t.o. .:
..X 2. = SAE B 146, 1 mm
..Y 3. = ital. 105 mm
Stub.-shaft gov. side p.t.o.:
.2 = cyl. shaft SAE, 1 “
.3 = ital. stand, tap shaft 30 mm
.4 = tap. shaft acc. SAE
.6 = ital. stand, tap shaft 23 mm

Gen_04_01_E_07.05
List of engine families, types and versions / page 2
Range Bore x
Typ-
and Basic types stroke Versions Remark and explanation of code letters
colour (mm) No.

8.. * E 80.. 80 x 100 15 ) E = Single cylinder

E 85.. 85 x 100 14 ) E.. ..FG = Flangeable on flywheel side
red E 88.. 90 x 105 55 ) ...FG ....G = Heavy-flywheel version; not flangeable
E 89.. 90 x 105 11 ) .....G

9.. * E 950 95 x 105 44 --- E = Single cylinder, generally equipped with counter rotating
orange balance shaft; hydr. pump directly flangeable

G.. 2 G 30* 88 x 75 82 ) “H” 2 = Two-cylinder type

light 2 G 40 92 x 75 91 ) “H” = prepared to fit a hydraulic pump (introduced as a separate
green version in ‘97, before included in standard build)

Z..* Z 782. 82 x 100 32 ) 2 = Two-cylinder type

Z 788. 90 x 90 48 ) ...H “H” = two positions for flanging hydraulic pump
brown Z 789. 90 x 100 49 )
Z 790 90 x 100 37 )

M.. 2 M 31* 102 x 90 84 ) 2-, 3-, 4-cylinder

3 M 31* 102 x 90 85 ) H = High swirl cylinder head + special camshaft for more power
green 4 M 31* 102 x 90 86 ) in the speed range n 2300 min -1
) (LS) = initially named the “low speed” version
2 M 40* 102 x 105 78 ) ..H(LS) L = Low swirl ylinder head + standard camshaft for operation
3 M 40* 102 x 105 79 ) ..L speed 2300 min -1
4 M 40* 102 x 105 80 ) ..Z Z = With counter rotating balance shafts
)
2 M 41 102 x 105 105 ) 2 - 3 - 4 M 41: no versions “L” or H”
3 M 41 102 x 105 106 )
4 M 41 102 x 105 107 )

L.. 2 L 30.* 95 x 100 51 ) 2 - 3 - 4-cylinder

3 L 30.* 95 x 100 52 ) .S = semi-capsuled, no counter rotating balance sahfts
dark 4 L 30.* 95 x 100 53 ) .Z = semi-capsuled, with counter rotating balance shafts
blue ) .C = capsuled, with counter rotating balance shafts
2 L 31.* 102 x 90 68 ) .K = capsuled, without counter rotating balance shafts
3 L 31.* 102 x 90 69 ) (with 4-cylinder versions at n 1800 min -1only)
4 L 31.* 102 x 90 70 ) ..H = High swirl cylinder head + special camshaft for more power
)..S* in the speed range n 2300 min -1
2 L 40.* 102 x 105 64 )..Z*
3 L 40.* 102 x 105 65 )..C Versions S - Z:
4 L 40.* 102 x 105 66 ) from 1993 on part of the M-range, in which semi-capsulation is
)..K available as additional equipment
2 L 41 102 x 105 102 )
3 L 41 102 x 105 103 )...H 2 - 3 - 4 L 41: no versions “H” (high swirl cylinder head)
4 L 41 102 x 105 104 )
)
H 2 L 30.* 95 x 100 60 )
= BMW: D 20/D 35 H. = watercooled
)
H 3 L 30.* 95 x 100 61 )
= BMW: D 50 )

W.. 2 W 35 70 x 90 114 ) W = watercooled

3 W 35 70 x 90 115 )
light 4 W 35 70 x 90 116 ) T = Turbo
blue )
3 W 35 T 70 x 90 122 )
4 W 35 T 70 x 90 123 )

* = out of production

07, 2005
VME-mh-es

Gen_04_01_E_07.05
 2

Type plate data

Type plate data with sample figures
Standard type plate, from 11-2000 onwards
applied to engines only that are not certified
Type code for complying with EU exhaust gas emission
legislations
Engine serial code
HATZ-Codes 01 - 02 - 03
Year of production

Current production number

073 15 98 026315 previously 12; now 13 digits (as first digit "0" or "1" added) Customer specification
ENGINE NUMBER
Power setting code
Explanation of "NH" - (sample figures)
1 D 81 Z
Type, version Value Unit Reference applied with engine range
1)
(pto.-configuration ) TYP KENNZ. 6,20 Degree of cranking angle 1 B..
not generally applied
1 D 81 Z 36 151 h 1,20
for duration of injection
mm Effective injectionstroke E 5/6 - 7.. / 8.. /
MOTOR/FABRIK NO. ABE/AUSF. of pump plunger 9.. / D... / Z... /
0731598026315 2 G.. / L/M 31-40
MIN-1 NH PV CM 3 - 017 mm Rack position at full laod
3000 / 150 1,17 150 measured from
"O" (= centre) in 1/100 mm
L/M 31-40-41
2) with injection pump
PFR 1 K 80 .. only
3) with injection pump
3000 150 PFR 1 K 90 .. only

Nominal load speed

Speed increase under
no-load condition Adjustment instruction no.: special adjustment
Max. no-load speed MADE IN GERMANY 032 255 04 procedure(s) regarding engine speed, power
3000 + 150 = 3150 min output, etc. (not generally applied)

Ed. 12,00 - MSS-schi-es Gen_6_1_E_12.00

 E inheits-Typenschild für E U und E PA
Unified type plate with E U as well as E PA
P = 19...75 kW Ed. 12, 2000
MSS-schi-es

Beispiel mit HATZ codes

Sample with 3 M 41 Z 39 - 40

IMPORTANT ENGINE INFOR MATION

MOTORENFABRIK HATZ + KG GMBH
CO Production
D-94099 RUHSTORF Monat + Jahr
Month + year
nur für EPA ENG.FAM. BUILD DATE
only for
XHZXL3.43A37 0399 Prüfvorschrift
TYPE / SPEC. MIN -1 PV Spec. adjustment and
test procedures
3M 41 Z - 152c 10,01) 2500/180 208
Leistungs-Kennzahl
SERIAL NO. NH / kW CM 3 und Nennleistung
1061699007428 +075 36,9 2574 Pump setting code and
nominal power output
EC-TYPE-APPROVAL-NUMBER
el*97/68CA*00/000*0046*00
This engine conforms to MY 99
1998 U.S. EPA regulations Hubraum
nonroad compression-ignition engines. Refer to owner’s
manual for maintenance specifications and adjustments. Swept volume

Made in Germany 041 280 00

nur für EU:

Zusammensetzung der EG-Genehmigungsnummer:

el * = Genehmigung erteilt in Deutschland
97/68CA * = Richtlinie 68, die in 1997 von der EG verabschiedet worden ist.
Leistungsklasse C 37...75 kW; Anwendungsfall A (”D”= 18...37 kW)
00/000 * = Nummer der Änderungsrichtlinie
0046 * = 46 Genehmigung, die vom KBA gemäß Richtlinie 97/68/EG erteilt worden ist
00 = Nachtragsnummer für evtl. Änderung in der Genehmigung
1) = bei allen EPA-Typenschildern muß der Nenn-Förderbeginn mit angegeben werden

for EU only:

Composition of the EC-type-approval number:

el * = approved in Germany
97/68CA * = directive 68, released in ‘97; C = output classe 37...75 kW (D = 18...37 kW)
00/000 * = number of modification of directive
0046 * = approval No. of German Approval Authority (”KBA”)
00 = additional code for modifications with “KBA”

1) = with all EPA-type plates must be indicated the nominal pump timing (begin of
delivery)

11, 2000 Gen_6_2_D_E_11.00/1

MSS-schi-es
 3

Operation and
maintenance
 Maintenance sticker
Engine range 1B..

IN 0.2 mm
0.008 "
EX 0.2 mm
0.008 "

8 - 15 250

500 1000 051 104 03

IN 0.2 mm
0.008 "
EX 0.2 mm
0.008 "

8 - 15 250

500 1000 051 104 03

VME / KA 06.2005

Allg_8_1_B_Mot_06.05
 IN 0.1 mm
EX 0.2 mm

1D90
IN / EX 0.3 mm

1D..

040 484 03
Recommended lub.-oil viscosity classes
with reference to ambient temperature
- lower border lines refer to lowest possible temp. at
start-up of engine with regards to pumping capability and
internal friction

- upper border lines indicate highest possible temperature for sufficient

o
viscosity reserve under the presumption thatoil
t max = amb.
t + 100 C

°F °C OIL: SAE...
122 50

104 40

86 30

40
15W/40
10W /40
5W/40

30
10W /30
5W/30
68 20

10W
50 10

32 0

14 -10

-4 -20

-22 -30

-40 -40

Ed. 03, 2002

MFW-pk/
MFS-schi-es Gen_8_3_3_E_03.02
 Lub.-oil quality specifications

ACEA
(Europe)

new: (introduced in 2001)

engine worldwide standard DHD 1

manuf.
specs.

mod. 04, 2002

API (USA) MFS-schi-es

Gen_8_3_4_D_01.01
Gen_8_3_4_D_10.99
 4

Technical features and

adjustments in general
 1 B..
DIRECT INJECTION ENGINES
1 D..
Sequence of aspiration and combustion 2 G 30/40 Ed. 02,2002
MFS-schi-es
L/M-range

Injection of fuel into the

compressed and still rotating
Aspiration of air through air for equal distribution and Firing
the spiral type inlet port best possible atomizing

Gen_3_6_E_02.02
Crankcase breather valve
with L/M - D.. - 2 G.. engines Ed.10, 2000
MFS-schi-es
to inlet
port
Stage I
Crankcase pressure lifts
diaphragm from seat and
gets released into suction
strainer positive crankcase
pressure
from
crankcase

to suction
Stage II strainer
Vacuum, forces the diaphragm
onto its seat and blocks air flow
from crankcase. Opens only connection
when positive pressure inside to atmos- vacuum
the crankcase is higher than phere
the vacuum
from
crankcase

L/M_D_G_M31_E_10.00
Gen_9.2_e
 Ed. 04, 2001
MSS-schi-es

A B C
Standard-Sacklochdüse Sacklochdüse
Standard sac-hole nozzle mit reduziertem Sackvolumen Sitzlochdüse
Injecteur à trou borgne Sac-hole nozzle Seat-hole nozzle
standard with reduced sac-volume Injecteur à siège perforé
Injecteur à trou borgne avec 1 B 20 "CARB" + “EPA”
1 D 30 - 35 - 40 - 60 - 80 volume mort réduit
1 B 30 / 40 “EPA”
2 G... / Z 7... 1 D 41/ 50 / 81 / 90 “EPA”
1 D 31 / 41
L / M 30 - 31 - 40 L / M 41
1 B 20
2 G 40 “EPA”

marking marking
DLLA DSLA

Gen_9_4_d_e_f_04.01
 Graphical presentation of speed setting
Sample: 1 D 41 S - 170 b...c
Ed. 07,2004
MFS-mh-es

Type plate indication as per Type plate indication as per

previous HATZ setting standard: actual standard: complying with EPA-rules
2900 / 100 2800 / 200

% load % load
total speed drop total speed drop
100 200 rpm 100 200 rpm

50 50

0 0
2800 2900 3000 2800 2900 3000
Speed at full load Speed at full load
average load average load
no load no load

Result: although type plate indications are different:

at same working conditions the engine in both cases would run at the same speed
1D_A90_E_01_07.04
 Verschleißhülsen für Wellendichtringe
Wear sleeves for shaft seal rings
Douille d’usure pour joint d’étanchéité
Manguito de desgaste para retén Ed. 09, 2001
MSS-schi-es

1. Anwendungsübersicht / application schedule / tableau d’emploi / tabla de empleo

Wo zu verwenden? / Where to fit ? / Endroit d’emploi ?

Ident-No. Sitio de empleo ? Type
(mm)

502 893 00 70 Kurbelwelle schws / crankshaft flywheel side / vilebrequin L 30

côté volant / cigüenal lado volante
037 806 00 80 - ditto - L 31/40, M 31/40

502 894 00 55 Antriebswelle sts. / drive shaft gov.side / arbre de sortie L 30/31/40,
côté distr. / arbol de salida lado distr. M 31/40
504 144 00 62 Kurbelwelle schws. / crankshaft flywheel side / vilebrequin 1 D 60-80-81
côte volant / cigüenal lado volante

2. Montageanleitung / mounting instructions / instruction de montage / instruccion

de montaje
2.1 2.3
Kontaktzone entfetten und Loctite 648 auftragen. Nach dem Aushärten (ca. 1 h) den Montagebund
Degrease contact area of shaft and apply Loctite 648. an der Sollbruchkerbe ablösen.
Dégraisser la zone de contact et enduire avec du After fitting and bonding (approx. 1 h) cut off
Loctite 648. mounting edge.
Desengrasar la zona de contacto y untar con Après montage et sèchage de la colle (env. 1 h)
Loctite 648. couper et enlever le collet.
Despues del montaje y secarse (ca. 1 h) cortar
2.2 y sacar el reborde de montaje.
Verschleißhülse bündig mit Innenrad der Außenfase
aufziehen.
Fit sleeve flushing with inner edge of taper.
Monter la douille a fleur du bord intérieur du chanfrein.
Montar el manguito hasta el borde interior de la fase.

Sollbruchkerbe / rated
break groove / entaille de
rupture / entalla de ruptura Gen_10_5_D_E_F_09.0
 5

Function of components,

adjustments and repairs

engine range 1 B..

 Nockenwellen mit Dekompressionsautomatik
1 B 20 - 30 - 40 - (V/W) Camshaft with integral decompression device
Ausführungen und Reaktions-Drehzahl - Executions and reaction speed
Ed. 02, 2002
MFS-mh-es
cplt. 3)
S

1 B.. react.
Ident-No. n = 4) Ident-No. S = mm1)
A B C D E F G
1a --- x ----- 015 035 22 200 - 220 013 265 01 11 … 11,5
20 / 30 1 b x x Hitachi 013 650 013) 160 - 180 013 649 003) 9 … 9,5
1c x 2) Iskra 015 035 22 200 - 220 013 265 01 11 … 11,5

2a --- x -----
20 / 30
2b x --- Hitachi 5) 013 650 013) 160 - 180 013 649 00
3)
9 … 9,5
V
5)
2c x --- Iskra
3a --- x ----
40 013 450 02 200 - 220 013 265 01 11 … 11,5
3b x 2) Iskra
40 4a --- x ----
V/W 4b x --- Iskra 5) 013 651 013) 160 - 180 013 649 003) 9 … 9,5
1) Aufgrund von Toleranzen in der Federkennung des Drahtbügels können sich Abweichungen ergeben. Im Zweifelsfall eine dynamische Funktionsprüfung
(wie in der WSI 99.161 beschrieben) durchführen.
Due to possible tolerances with the rating of the spring these dimensions may need to be slightlyltered.
a In case of doubt, carry out dynamic test as per WSI 99.161.
2) Reversierstart vorhanden oder nachrüstbar, Nockenwelle mit Deko-Automatik verbaut / recoil start stalled
in or retrofit possible, camshaft with deco-aut. integrated
3) Gelber Farbpunkt - Nockenwelle mit Fliehgewicht für Elektrostart / yellow paint mark - camshaft th
wicentrifugal weight for electric start
4) Nockenwellendrehzahl / camshaft speed
5) serienmäßig bei Elektrostart keine Deko-Automatik integriert
1B_M04_02.02
1 B 20 / 30
Nockenwellen - camshafts Farbmarkierung
1)
Fliehgewicht - centrifugal weight 013 265 00 Paint mark Ed. 10, 1999
MSS-schi-es
gelb - yellow
Positionierung (Vorspannung der Feder)
Positioning (pre-tension) of spring

Nockenwelle- camshaft
016 403 00
1)
Reaction bei - with
- + n = 360 ± 20 *
(180 ± 10 **)
S = 9,0 … 9,5
* = Motor / engine
** = Nockenwelle / camshaft

Nockenwelle- camshaft
016 404 00

Reaction bei - with Bügel (Rampe) für Dekompression

n = 440 ± 20 * Cam-lever for automatic decompression
(220 ± 10 **)
S = 11,0 … 11,5
* = Motor / engine
** = Nockenwelle / camshaft

1B_M04_10.99
Nach Eindichten Laufbuchse mit KG mittels Vorrichtung verspannen
After applying with Loctite 574, clamp cylinder sleeve in crankcase
with a device
Zyl.-Laufbuchse mit LOCTITE 574 eindichten
Dichtm.-Auftrag max. 01in KG-Innenkante
Sealing of clyinder sleeve with Loctite 574
Apply Loctite 574 max 0.1 at inner edge of
crankcase

Gilt offiziell nur für den 1 B 30;

wird aber von unseren Werk-
stätten bei Reparaturen auch am
B 20 angewandt.
Bei B 40 nicht notwendig, weil
dieser O-Ring -Abdichtung hat.
Valid for 1 B 30 only; in our workshop
also used on 1 B 20. For1 B 40 engines not
necessary caused by O-ring sealing

Mounting instruction - cylinder sleeve in crankcase

1B_M05_D05_11.97
1B_M05_E01_11.97
 Speed setting with internal limitter
Technical instruction
1 B... segment (finger plate) 951 344 00
Eccentric for high idle speed; basic Eccentric for low idle
position at pre-assembly should be speed; not generally
approx. 5 h in use!
051 786 00
2
B

1 3

D Additional eccentric
(for EPA only); not yet
introduced!

051 788 00 (2 x)
C
In case that the adjusting range of eccentric “1” is
not sufficient: re-position finger plate relative to speed
control shaft as per following sketch: 051 786 00
Lock plate; also to fix O-ring
into seat (fix with screw “D”)

for higher for lower

speed, final tuning of speed with eccentric “1”.
Ed. 11, 2000
1B_M32_E15_11.00 MSS-schi-es
1 B.. Static setting for spiral spring governor / Page 1

Ed.03,2006
VME-mh-es
-1
n > 1900 min

Start Chisel mark

B
D
- Position eccentric screw A to 5 h (chisel
mark corresponds with inner pin) for engines
1 B 20/30 or 6 h respectively engines 1 B 40 C
D - Position and set spring attachment blade E E
to proper length (dimension )Sas indicated
on reference table
- Hook in spring to corresponding bore n < 1800 min -1
- Force governor lever into STOP position and
fix somehow
- Turn speed control lever Btowards position
“Start” until pretension of spring (dim. )L
corresponds with required value as per
data chart
- With this very position turn plate Cuntil left
finger comes to contact with eccentric pin,
and finally lock on speed control shaft D. D

C
E

1B_M10_E04_P1_03.06
1 B.. Static setting for spiral spring governor / Page 2

Ed.03,2006
VME-mh-es

Execution I Execution II

Start Chisel mark

or

4x2 Flyweights 4x1 Flyweights

B
d=1,0 d=0,9

D
Attention:
Wire diameter “d” of spring depends
on execution of flyweight carrier
Notes:
Individual speed values refer
to rated full load speed.
Final (dynamic) speed tuning at test
bench being done by slightly turning
eccentric screw A accordingly.

2000 2500 3000 3500

1B_M10_E04_P2_03.0
 1 B 20 - 30 - 40 (V) - Injection equipment
* = now: EPA conform Ed. 05,2002
1 B 20 (-V) injector complt. with high pressure pipe MSS-schi-es
1)2)
Pos. 34 41 43 48 1* 55 31 33
mm 4
Serial- mark. mark. mark.
No. Ident-No. mm A B A B mm Ident-No. Ident-No. Ident-No. A B Ident-No. Spec.

4) 1 B 20:
48 10 22 01322200 435 01621600
1 6,5 B 903 0,5 (01326100) 180 01326100 50442200 DLLA 634
1 B 20 V: (01331200) 9,203 053 160P634
10 12 830
356 05070500 Cu
1 B 20:
23 01322210 01621610
6,5
F533 V064
903 0,5 (01655400) 250 01655400 50489300 DSLA 992
2 1 B 20 V: (01349600) 9,03 088 160P992
47
13
1)
4) Special nozzle für CARB: DSLA 160 P 807 A mark. B 807; no longer available
2)
46 1 B 30 (-V) Special equipment for LWA 100: Nozzle DSLA 158 PV A mark. B Pump spare part set - see line 1

28 Pos. 34 41 43 48 1* 55 31 33
45
34 Serial- mark. mark. mark.
mark. A 29 No. Ident-No. mm A B A B mm Ident-No. Ident-No. Ident-No. A B Ident-No. Spec.
44
mark. B 30 3 10 16 01322200 930
43 6,5 435 B 01724600 01746000 50442200 DLLA 634
(01331200) 9,203 053 356 903 0,5 180 160P634

05070500 Cu
3)
42 17
55 31 4
01582900
7,0
V012 F514 F02 01328800 01328900 50468000 DSLA 789
1 B 30 V: (01332800) 903 9,03 011 903 0,5 (01363200) 220 155P789

41 mark. Bmark. A 10

mm mark. B 1 B 40 (-V)
Pos. 34 41 43 48 1* 55 31 33
32 mark. mark. mark.
mark. A Serial-
Ident-No. mm A B A B mm Ident-No. Ident-No. Ident-Nr. A B Ident-No. Spec.
No.
V 070
01680800 903
5 10 F541 930 01622800 DSLA
33 (01622901)
7,5
356 903 0,5 (01347400) 05070500 Cu
D 016 9,03 220 01347400 50501200 155P 1029
A 10299
01707600

3)
Disc 42 being deleted on section 2 for 1 B 20
4) For 1 B 40 technical version variants slightly from instruction 1B_M14_E02_05.02
mit EPA-konformer Einspritzausrüstung - with EPA conforming injection equipment
Positionierung und Funktion von Start- und Last-Steuerschlitz im Pumpenelement
Design and functional effects of “start”- and “load”-section control slots of pump plunger Ed. 06, 2001
MSS-schi-es
Alle angegebenen Werte (außer mit “1” gekennzeichnet) und zeichnerische Dimensionen sind annähernd und lediglich zur Verdeutlichung
der Funktion dargestellt; die Werte beziehen sich beispielhaft auf den Motor 1 B 20
All indicated values (except of the one marked “1”) as well as dimensions are “approx.” and refered to for explanation reasons only;
indicated values refer to 1 B 20
Start, Hochlauf und Überlastbetrieb bei kaltem Motor Normal-Betrieb unter Last (dargestellt: etwa Halblast)
Start, acceleration, and overload operation with Normal operation under load (indicated: approx. medium load)
cold engine
Kurbel- und Zünddrehzahl Hochlauf
Cranking- and initial firing C Acceleration B n = min -1
n = min -1 1200 2300 3600
300 3600

später
Förderbeginn früher
intermediate Förderbeginn
e d b a
retarded advanced
timing timing
8o =B= 18 o
B= 15 o 1) 17 o 2) 20 o 2)
o 3) 3) o 3)
(15) mm 3 (18) Q e 12 14 o 16
1) offizieller statischer Einstellwert für 1 B 20 bei nnom = 3000 min-1
B = Förderbeginn / begin of delivery official statical adjustment value for 1 B 20 with nnom = 3000 min-1
2)
E = Förderende / end of delivery theoretischer Wert, nicht statisch meß- und einstellbar
S = Einspritzhub / effective injection stroke theoretical value, statically not verifiable 1B_M14_D_E09_06.01
die Unterschiede sind hier zum besseren Verständnis 3)
resultierender, dynamischer Spritzbeginn / resulting dynamical start of injection
leicht überzeichnet dargestellt
Replacement of pump element
- working sequence, and
- important advices to avoid mistakes that bear the risk of sequential
malfunctions

- Prior to any dismantling action: carefully clean and dry off the working area with the
engine as well as the surroundings to make sure that no dust and / or water enters the
fuel system

- Take off the side cover to get access to the inner components of the pump, but do not tu
the tiny grub screw off its position!

- Remove closing cover or stop units

- Make sure that pump rocker arm is in BDC-position

- Unhook the transfer clip that connects the rocker arm to the pump plunger. This operatio
is easy with the pressure valve holder not yet removed or loosened!

- Now remove the pressure valve taking care that none of the tiny bits and pieces get lost

- Pull out the pump element by means of a tapered pin (made from wood or plastic, simila
to a pencil) that gets slightly forced into the bore of the barrel. As an alternative a magn
took can be used as well, but this must not be forced into the bore!

Important note: Prior to lifting off the element prevent the control sleeve from dropping
down by holding it with a finger and then locking it by putting a suitable pin or screwdriv
through the bore.

This prevention measure is not required with engines of production year 2000 and later
these are equipped with a fixation loop.

- Under the barrel is to be found a spacer shim whose thickness has to correspond with th
number stamped into the surface of the front cover. Thereby the injection timing gets
adjusted: thinner shim means more advanced, and vice-versa.

- Prepare a new pump element by carefully rinsing it in clean fuel to wash off any dust
particles, dry off and apply grease to the upper section of the plunger to make it sticking
the bore.

- Fix pump barrel to the afore mentioned “pencil” and engage the pump plunger, taking c
for lowest possible position and proper radial position: control helix has to face the radi
supply bore in the barrel.

1B_M14_E06
- Prior to engaging the pump element position the control sleeve in the centre of, as well
the parallel axis to the installation bore. Radial position of sleeve and control hub of the
plunger also need to correspond to enable easy engagement.

- Fit spacer shim into bore.

- Check for the proper positioning of eccentric pin. In case of irregularity: force slightly in-
outwards.

- Carefully engage the pump element; especially with regards to lining up the longitudina
slot in the barrel with the eccentric pin (slight turn the element via the guiding rod until i
“drops” into the seat).

- Proper end position of element gets approved

- radially being locked
- top face of barrel being flush with lower end of M 20-thread in bore, and / or having a
recess of approx. 7 mm to upper face.

- Insert pressure valve components in the proper sequence.

Note: If during dismantling a spherical washer was found on top of barrel: re-insert it. Th
washer got introduced during a defined production period and with defined executions
engine, but not in general!

- Before fitting the pressure valve holder (pressure pipe connector) check the O-ring for
good condition. If necessary: replace

- Check the entire control mechanism for free movement

- Now it is time to re-engage the transfer clip to the foot of the barrel.

- Before connecting the pressure pipe: open the fuel supply and slowly crank the engine
some 10 - 15 turns (with the throttle lever in full “run”-position).
Thereby possibly-entered dust particles will be “flushed out” before they might find thei
(wrong) way into the injector.

- Now connect the pressure pipe, but with the injector still off it's seat in the cylinder head
Again crank the engine some 20 injection strokes to check for a regular spray pattern
before installation.

- Finally re-install EPA-protection components and -sealings if required (refers to engine

in, or destined for USA only). With all other engines, even if originally equipped with,
these devices do not more need to be fitted.

MFS-schi-es
Breather- and non-return valves for the low-pressure fuel system system, as having been in use
with all engine families; standard- as well as OEM-specific executions
Ed. 01, 2001
MSS-schi-es

spring loaded, without by-pass, “Pierburg” - “APG”

Ident-No.
502 542 00 503 546 00 503 462 00 503 434 00 503 337 00
008 055 00 / 01 016 769 00 d a =6mm d i =4 d a =4mm d i =2 d a =4mm d i =2 d a =8mm d i =6 d a =8mm d i =6
015 346 00
Pö* =
Pö* = 10...15 mbar Pö* = 150...200 mbar Pö* = 10...15 mbar
150...200 mbar
* (Pö = reaction pressure)

black beige di black black all black all

all-over all-over over over

white
with without black top
Spezification

yellow
by-pass by-pass
dot
beige
body-section
Steel Teflon-
ball ball without
by-pass 7.21.381.03

grey grey
Steel ball

da
Weigth: 4 g Weight: 3 g Weight: 4 g

all single cylinder 1 B 20 / 30: 1 B... 1 D.. 2 G 30 / 40: 2 G 30 -172 a: L/M 31-40-41: HL 30 Z-154 a:
Application

engines: with earlier pair-wise in instead of in connection with and earlier in case of low OEM-specific
Exeption execution of fuel symmetric arrange- 00805501 in case electrical fuel execution of positioned fuel tank, equipment
see 015 346 00 system ment inside the fuel of mechanical oil shut-off valve standard and with no “start (”Dynaf”);
(horizontal conn. tank for extreme pressure shut-off equipment; later release” device no other use!
1 B 20 / 30...: of supply hose) tilting position system on replaced by
with new execution (”slant-valve”) 50354600
of fuel system 1 B 40: generally (L-) M 31-40-41
(vertical connection instead of 50343400
of supply hose) in case of low
positioned fuel tank

Gen_10_2_E_01.01
 1 B 20 - 30 - 40
Anbindung des Entl.-Rohres (PVC) zum
Öl-Absorber-Einsatz (Filz-Pfropfen) Ed. 06, 2005
MSS-schi-es
Connection of crankcase breather-tube to
oil-absorption plug (felt)

1. Rohr mit Überstand in 2. Filtereinsatz auf Maß 12 mm in 3. Rohr zurückziehen bis

den Ölabscheider einführen den Ölabscheider einschieben Filtereinsatz und Rohr
Insert breather tube to separator bündig abschließen
Position absorption plug as
housing as to have the slanted tip indicated Pull back beather tube as to
facing a few mm out obtain the tip being flush, but
in good contact with inner end
of plug

1B_M31_D_E01_02.02
 Montagehinweis / Installation instruction
Instructions de montage / Instrucciones de montaje
Ed. 05, 2005
TA-Ge/
Standard-Entlüftung geschlossene Ausführung Standard-Entlüftung geschlossene Ausführung VME-mh-es
Standard execution closed execution Standard execution closed execution
Reniflard version standard retour dans le carter du filtre à air Reniflard version standard retour dans le carter du filtre à air
Respiradero del bloque - version standard retorno en la caja del filtro de aire Respiradero del bloque - version standard retorno en la caja del filtro de aire

Gasaustritt ins Loctite 406

Freie vom Entl.-Ventil Loctite 406
Gas outlet to from breather
atmosphere valve
Sortie des gaz
à l’extérieur
Salida de gases
al exterior

Filtereinsatz Filtereinsatz Filtereinsatz Filtereinsatz

Filter insert Filter insert Filter insert Filter insert
Filtre / Cartucho Filtre / Cartucho Filtre / Cartucho Filtre / Cartucho

Standard-Entlüftung geschlossene Ausführung Standard-Entlüftung geschlossene Ausführung

Standard execution closed execution Standard execution closed execution
Reniflard version standard retour dans le carter du filtre à air Reniflard version standard retour dans le carter du filtre à air
Respiradero del bloque - version standard retorno en la caja del filtro de aire Respiradero del bloque - version standard retorno en la caja del filtro de aire

Gasaustritt ins Loctite 406

Freie Gasaustritt ins Loctite 406
Gas outlet to Freie
atmosphere Gas outlet to
Sortie des gaz atmosphere
à l’extérieur Sortie des gaz
Salida de gases à l’extérieur
al exterior Filtereinsatz Filtereinsatz Salida de gases
Filter insert Filter insert al exterior
Filtre / Cartucho Filtre / Cartucho Filtereinsatz Filtereinsatz
Filter insert Filter insert
Filtre / Cartucho Filtre / Cartucho

1B_M31_D_E_F04_05.00
 “a” Ed. 04,2003
MFS-mh-es

Versteifungsring zum Tank-Hals

Einbaulage des Tank-Entlüftungsventils Re-enforcement ring for tank filler neck
Installation of fuel tank breathing valve Collerette de renforcement p.l’orifice de
remplissage du réservoir
Lage des innenliegenden Ventils wird von
außen durch den Längsschlitz “a” angezeigt Casquillo de refuerzo p. la boca del tanque

Standard-Ausführung
Standard execution
051 552 00
A Version standard
Ejecución normal

Nachrüst-Version
Retrofit-version 051 617 00
B Version montage ultérieur
Ejecución p. montage ulterior

1B_A01_D_E_F05_04.03
 1 B 20 / 30
Drehzahlverstellung für Bowdenzug - speed control device for bowden cable
015 635 01 cplt. Bestell Nr. - order code 100 Z 09 A Ed. 04,99
MSS-schi-es

Rückzugsfeder - return spring Mit dieser Ausführung muß im

051 540 00; Bowdenzug ein Stahldraht (oder
serienmäßig nicht eingebaut biegesteifes Seil) verwendet
not applied with the standard werden, damit auf "Stop" ge- 1) Wenn diese Rückzusgfeder eingebaut wird,
drückt werden kann. Die
build Bowden-hülle muß dazu aber in muß dazu eine stärkere Kompensationsfeder
den Schraubnippeln gefesselt (1,8 x 9,2 x 38) 504 832 00 eingebaut werden;

Beispiele der freien Postionierung - Samples of free positioning

sein. damit gilt dann: lmin = 31,5 mm
This execution requires a solid
In case of return spring installed: a stronger
wire (or stiff cable) to push for compensation spring 1,8 x 9,2 x 38 -
"stop". In addition, the bowden Ident-No. 504 832 00 - is needed.
spiral needs to be locked in the In this case refers l min = 31,5 mm
end pieces against pulling out.
504 830 00 Halter - support siehe - see correleation
051 176 00
diese Schraube
entfällt; no screw

Stütze - bracket
l min. 1) 051 175 00 Führungsbuchse / guide bush
= 25 ,5mm
051 650 00
Kompensationsfeder
(wird nur mit Kompensationsfeder 504 832 00 verwendet;
compensation spring
to be used with compensation spring 504 832 00 only;
504 846 00 / 1,0 x 5 x 33 1) nicht mit - not with 504 846 00! )

504 831 00 / 2 x

Bowdenzug so einstellen, daß bei Endanschlag des Handhebels in n max-Stellung - l min.= 25,5 mm nicht unterschritten wird.1)
Andernfalls könnte die motorseitige Verstellmechanik überlastet werden.
Set end-position of hand lever at n max -position to not undergo l min. of 25,5 mm.1) Otherwise the engine-side mechanism could
be overloaded.
CORRELEATION:
Rückzugsfeder Compensationsfeder / spring Führungsbüchse
return spring Ident-No. dim.(mm) l min mm guide bush 051 650 00 1B_A09_D_E02_04.99

nein no 504 846 00 1,0 x 33 25,5 nein no Montage- und Einstellhinweis 051 670 00
Assembly- and adjustment instruction + 051 679 00
ja yes 504 832 00 1,8 x 38 31,5 ja yes
 EPA High idle speed specification list

Speed range High idle speed HATZ Ident-Nos.

(min-1) (min-1) Governor lever Governor weight

1B_M32_E20
 6

Function of components,
adjustments and repairs
engine range 1 D…
 Ed. 02, 2001
MSS-schi-es

Vol.

Type
mm mm cm3 S T Z U C
1 D 30/31 86 65 377 X X X X X
A 1 D 35 86 65 377 X X X X

(A) 1 D 40 86 65 377 X X X X
(A) 1 D 41 90 65 413 X X ** X X ** X

1 D 50 97 70 517 X X ** X X **
1 D 60 88 85 517 X X X X X
1 D 80 100 85 667 X X X X X
1 D 81 100 85 667 X X X

1 D 90 104 85 722 X X
1 D 90 * 104 85 722 “V” “X” ** “W” “Y” **
* = liegend bei vertikaler Kurbelwelle / horizontal cylinder with vertical crankshaft / cyl. horizontal avec vilebrequin vertical /
cilindro horizontal con cigüeñal vertical ** = werden in 2001 auslaufen! Gen_4_1_D_E_F_S_02.01
 Schmierölkreislauf / Lubricating circuit / Circuit de lubrification /
Circuito de engrase

BISHER - PREVIOUSLY - ANCIEN

Öldruckschalter
Motoren / Engines Oil pressure switch
Manocontacteur d'huile
Moteurs / Motores Manocontacto de aceite
S-Z-C
(linksdrehend /
anti-clockwise
rotation / Sekundärkreis
Secondary circuit
rotation à gauche)
Circuit secondaire
Primärkreis Circuito secundaria
Primary circuit
Circuit primaire
Circuito primario

ÖL / OIL / HUILE /
ACEITE

Öldruckschalter
Motoren / Engines Oil pressure switch
Manocontacteur d'huile
T-U Manocontacto de aceite
(rechtsdrehend /
clockwise
rotation / rotation
Sekundärkreis
à droite) Secondary circuit
Circuit secondaire
Circuito secundaria
Primärkreis
Primary circuit
Circuit primaire
Circuito primario

ÖL / OIL / HUILE /
ACEITE

06, 97
MSS-schi-es 1D_M10_D_E_F01_06.97
 x
x xx
Marking
E d . 12 , 2 00 0
E d . 08 , 2 00 0

1 D ... S U P R A M S S -s c h i -e s

C a m sh a ft - a p p lic a t io n a n d - m a rk in g

1 D... S-Z-C T-U

Ident-No. stroke
Marking Ident-No. Marking
mm 6)

..30 - 35 - 40 040 240 10 1 D 20 L 040 370 00 1 D 20 R 7

1)
..31 - 41 040 895 00 1 D 41 L 040 894 00 1 D 41 R 7

..41 - 50 2) 041 371 10 50 L 8 041 372 10 50 R 8 8

..60 - 80 3) 037 970 20 1 D 60 L (040 222 00) (1 D 60 R) 7

4)
040 999 00 1 D 81 L 7) (041 000 00 )
4)
(1 D 81 R) 7
3)
..81 - 90
040 999 105) 81 L 9 (041 000 10 )
5)
(81 R 9) 9

7)
041 423 004) 1 D 81 L 7
V-W ---- ----
5) 90 V 9
2) 041 423 10 9
90
4)
041 000 00 1 D 81 R 7
X-Y ---- ---- 5)
041 000 10 81 R 9 9

1)
With injection pumps ..A 65 S 2004 (stroke= 7 mm) *
2)
With injection pumps ..A 70 S 2010 (stroke = 8 mm) *
3)
With 1 D 60 - 80 - 81 - 90: clockwise rotating versions with horizontal crankshaft (T - U) no more
in serial production
4)
To be used with injection pumps of the 7 mm stroke version only! *
5)
To be used with injection pumps ..A 80 S 3015 ( 9 mm stroke) only! *
6)
Stroke = lift of injection cam in “mm”: to be paired with injection pumps of identical stroke only
(see overview “injection equipment) *
7)
These camshafts are identically marked, but are of different length: 040 999 00 = 91 mm;
041 423 00 = 81,5 mm
* See overview “injection equipment” 1D_M04_E02_12.00
1 D 30 … 90 (SUPRA)
Start- und Kaltlaufregelung, öldruckgesteuert, und ihr Einfluß auf das Leistungs- und Drehzahl-
verhalten bei hydraulischen Antriebskomponenten
Start- and cold-run control device, oil pressure operated, available executions and their influence on
speed- and power characteristics with hydraulic p.t.o. components
Régulation du démarrage à chaud et à froid, commandé par la pression d’huile, et les influences au
niveau de la puissance et du régime avec des composants d’entraînement hydrauliques
Sobrecarga hidráulica y regulación termica del caudal de inyección

Hydraulische Startfüllung Temperaturgesteuerte Einspritzmengen-Regelung

Excessive fuel device “ Standard " Temperature-controlled injection-quantity adjuster °C °F
Surcharge hydraulique Ajustage quantité d'injection dépendant de la temp.
Sobrecarga hidráulica Regulación termica del caudal de inyección

A B A B C

9 mm 14 mm 18 mm
21 mm 26 mm

Betrieb - marche - Betrieb - marche - Betrieb - marche -

Start Start en marcha en marcha
en marcha
<40°C >40°C

A B A B C

< 45 °C > 45 °C
< 113 °F > 113 °F

= neff (min-1) = qeff (mm3) 1D_M12_D_E_F01

 Motoren nicht EPA-konform /
Motoren / Engines / Moteurs / Motores 1 D... SUPRA engines not meeting EPA-requirements

Bosch HATZ (compl.) BOSCH Ident-No. bar

(A) 1 D... HATZ n < 3000 n = 3600 Serial-No.
PFE 1... Ident-No. DLLA.. psi
Ident-No.
A B C D E F G H I
o
1 30 S,Z;T;U;C Q 65 / 52 503 835 005) 20,5 ±0,5 o
23,5 ±0,5 [ 10
503 652 00 170 P 260 503 832 00
2 35 S;Z Q 65 / 54 503 958 00 16,5o±0,5 [ 10
+8
3 40 S;Z;T;U Q 65 / 52 503 835 005) 200 20,5o±0,5
o
23,5 ±0,5 [ 10
+115
4a 504 153 00 2900
o 3)
31/41 S;Z;T;U;C 160 P469 504 154 00 20,5o±0,5 2)
23,5 ±0,5 [ 10
4b A65S2004 504 157 00 504 153 01
o
4c 41 S;Z;T;U 1) 504 490 00 160 P 664 504 491 00 16,5 ±0,5 ---- [ 10
60 S;Z,T;U
o
19,5 ±0,5 ---- [ 10 15 ]
Q 75 / 50 503 624 00
6 60 C 503 833 00 160S1181 503 834 00 21,5o±0,5 ---- [ 10 15 ]
o o
7 60 S;Z;T;U;C Q 75 / 55 503 624 104) 22,0 ±0,5 25,0 ±0,5 [ 16
250+8
8 80 S;Z;T;U +115
o
19,5 ±0,5 ---- [ 10 15 ]
Q 75 / 50 503 624 00 3620
9 80 C o
21,5 ±0,5 ---- [ 10 15 ]
503 571 00 158S1146 503 625 00 o o
10 80 S;Z;T;U 22,0 ±0,5 25,0 ±0,5 [ 16
Q 75 / 55 503 624 104)
11 80 C o
24,5 ±0,5 o
25,5 ±0,5 [ 16
12a 504 151 00 DLLA 154 P 504 152 00
474
81 S;Z;T;U,C 154P 504 152 01 235
+8
3)
13a A75S2005 504 162 00 504 151 01 DSLA 20,5o±0,52) 23,5o±0 [ 10
620 3400+115
14 90 DSLA 154P 504 152 01
504 151 01 620
1)
lärmoptimiert (nur für Stromerzeuger) / low noise version (for gen-sets only) / version à bruit réduit (pour gén. seul.) / version bajo ruido (para grupos electr. solam.)
2)
CARB certified engines: 19,0o±0,5 3)
CARB-certified engines:
o
22,0 ±0,5 Ed. 01,2000
4)
Ersatzteil-Nr. / spare parts no. / no. ident 051 186 00 (wegen Gehäuse-Nacharbeit / housing re-machined / à cause usinage carter MSS-schi-es
5)
Ersatzteil-Nr. / spare parts no. / no. ident 051 297 00 (wegen Gehäuse-Nacharbeit / housing re-machined / à cause usinage carter
1D_M14_d_e_01_01.00
 Injection equipment and timing
1 D 41 - 50 - 81 - 90
EPA-conformable
L

Engine Bosch HATZ (compl.) HATZ Begin of delivery,

Marking Ident-No. bar
Serial-No. PFE 1 A... Ident-No. and DSLA.. referred to nominal speed
Ident-No. psi
H=mm 1) marking H AT Z A B C D
A B C D E F G H I K

1 D 41 504 935 00 155 P 1003 1500- 1950- 2450- 3050-

1 S-Z-T-U 01 1900 2400 3000 3600
2)
18 ..70 S 2010 V 023 085 BOSCH 504 936 00 225 +8
..193 554;
alternative: 01 10o 12,5 o 15o 17,5o
S DSLA
L 8 mm alternative: 34 927 5)
1 D 41 C S 34 9255) 10o 12,5 o 15o 15o
504 752 01 F 02 016
504 751 00 1500- 1750- 2350- 3050-
1 D 50 F 521 9,03 01 504 794 00 1700 2300 3000 3600
2 S-Z-T-U
S = 53,6 ..155 P 839 225 +8
± 0,8 BOSCH 01
13 ..193 612 10o 12,5 o 15o 17,5o

1 D 81 S-Z
3
20 V 061 088
1 D 81 C 504 930 00
1 D 90 S-Z ..80S 3015 01
4
15 +12 1500- 1850- 2750- 3050-
L 9 mm 504 928 01 F 02 026 BOSCH ..160 P 990 504 931 01 270 1800 2700 3000 3600
02 ..193 559
1 D 90 8o 10 o 13o ---
5 X -Y-V -W F 532 9,03
+ 1,2
S = 59
11

1 D 81 S - Z 505 072 00 150 PV 3

6 3) BOSCH 504 997 00 --- --- --- 15o
20 38 4102
..002 076
1) L = Lift (stroke) of injection pump; see annex 2 for cross reference with corresponding camshaft
2) Initially lower pressure was applied: in case of replacement or repair, re-adjust to the actual val ue!
3) When nominal full load speed is equal or more than 3050 rpm: a different nozzle (and injector comp l. respect.) gets applied together with a seal ring (Cu) of 1.5 mm thickness (ident-no.
051 852 00) instead of the standard-one with 2.0 mm
4) Besides of camshaft some other key components, such as piston, cylinder head, crankcase, etc. got m odified as well. See IMT’s 37-00.598 - 602 - 603, and spare parts catalogue
434 200 72 - 07.00 for the actual build spec.
5)
Marking of components from alternative supplier.
1D_M14_e02_12.00
1 D 41 - 50 - 81 - 90, EPA-conform
- Ausgleichscheiben und Papierdichtungen für die Förderbeginn-Einstellung
- Spacers and gaskets for the timing Ed. 01, 2001
- Cales de compensation et joints en papier pour réglage du début d’alimentation MSS-schi-es
- Juego de cuñas-juntas por el ajuste del comienzo del suministro

27
2 D .x ke
ben
dic 2 D
i
1 D 41 - 50 3 che ints
d ie S de s jo 10* 3
ür nes eur s
10* rt f s
e nwe thick paiss junta 10*
hl f o r l ’é s -
10* Za ure pour cuñ 10* a
Fig leur las
Va lor de 1 D 81 - 90
Va

1
4
5 1
Papier - paper - papel
0,10 - 0,20 - 0,30 mm 12
Stahl - steel - acier - acero 5,7 mm
Nicht mit einrechnen! / Ignore for the calculation!
Ne pas prendre en considération dans le calcul
de l’épaisseur des joints!
No calcular por el espesor de las cuñas juntas!

15 13 11 6,7,8,9* 13 11 6,7,8,9*
PFE Stahl - steel - acier - acero PFE Stahl - steel - acier - acero
1A70S2010 0,3 - 0,6 - 0,9 - 1,2 mm 1A80S3015 0,3 - 0,6 - 0,9 - 1,2 mm

* Bauteile für die Bestimmung der Dicke des Ausgleichspakets / Components to be applied for the definition of the thickness of the spacer kit.
Composants pour la définiton de l’épaisseur du kit des joints de compensation / Componentes del juego de cuñas-juntas. 1D_M14_d_e_f_03_01.01
1D..
Einbauanleitung der Monoblockpumpe EPA II
Installation of “monoblock” injection pump as introduced for EPA II Ed. 10.2005
VME-haag
VMS-mh-es
Gleichstellung der Einspritzmenge: Einstellung des Förderbeginns:
Rißmarken genau auf Deckung bringen. Die Summe dieser beiden Zahlen (in 1/10 mm) definiert die
Dicke des Ausgleichscheiben-Pakets
Synchronisation of fuel quantity: (mind. 2 Dichtungen und eine Stahlscheibe verwenden).
Precisely match markings.
Adjustment of begin of delivery (”timing”):
These figures (in 1/10 mm), when added, define the
thickness of the spacer-kit (use min. two gaskets
and one steel shim only).
Beispiel / sample:
1,6 1.6 mm + 4 =0.4 mm = 2.0 mm

4 0.1 / 0.2 / 0.3 mm

0.3 / 0.6 / 0.9 / 1.2 mm
Pap.
0.1 / 0.2 / 0.3 mm
FE

Pap.

2 x 0.3 mm
- EPA II
- CARB 1 x 1.2 mm
mm
1 x 0,2 mm ,0
ta l2
To

645 020 00 644 991 01

1D_M14_D05_10.05_Beiblatt
Motoren - engines - moteurs - motores
1 D... SUPRA
Versionen S - Z - T - U
Ölabschaltautomatik mechanisch / Mechanical oil pressure shut-off
Vanne mécanique sur défaut de pression d'huile
Parada automatica por falta de presion de aceite
Kit 015 641 00 Einzelteile - components - composant - componentes
enthält zusätzlich eine Kraftstoffleitung, die nur bei Motoren mit Förderpumpe benötigt wird
additionally contains fuel hose, which is required for engines with feed pump only 034 935 00
comprend une conduite de carburant supplémentaire, seulement -slt. - pour moteur avec pompe d'alime ntation

036 743 00
Kraftstoffleitung
fuel hose
conduite de carburant
"Standard"

050 689 00 014 844 10

Entl.-Leitung
Venting hose
Purge d'air

014 528 10
+ 040 840 00(mont.)

036 623 00
014 800 00 Standard 500 011 00
(2 x)

012 489 01 500 158 00

mit Sieb
034 933 00
mit / with / avec 032 106 01

Ed. 12, '96

MSS-schi-es 1D_A11_D_E_F09_12.96
Motoren - engines - moteurs Ölabschaltautomatik mechanisch / Mechanical oil pressure shut-off
Vanne mécanique sur défaut de pression d’huile
1 D.... SUPRA Parada automatica por falta de presion de aceite

Rückschlagventil sep. Entlüftungsleitung für das Abschaltventil

non-return-valve sep. venting hose for the shut-off valve
clapet anti-retour cond. de purge d'air à part p.vanne de securite
valvula de retención conducto de purga independiente por la parada
automatica

Funktionsteile der Abschaltautomatik

Components of the shut-off system
Piéces fonctionnelles de la vanne de sécurite
Componentes de la parada automatica
Kraftstoffleitungen
Fuel hoses
Conduites de carburant
Conductos de combustible
Ölfilter-Gehäuse
Oil filter housing
Carter filtre à huile
Caja del filtro de aceite
Einspritzpumpe
Injection pump
Pompe d’injection
Bomba de inyección

Ed. 09,98
MSS-schi-es
1D_A11_D_E_F07_09.98
 Mechanical low oil pressure shut-off device
1D.. (modified execution)
Ed. 10,2005
VME-haag
VME-schi-es

Supply flow
Return flow
4 Non return
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lever

2
4 3 4 Non return
valve
1 (assembly)
Stop:
Functional data and description:
- Opening at 0,4 bar oil pressure (with cold engine) 3
- Lowest possible idle speed with warm engine: 800 rpm 2
(with oil level not below “min”) 1
Venting
- Reaction pressure (”stop”) at 3000 rpm: 1.0 bar lever
- Due to an additional non-return valve and modified arrangement of supply- and return
hoses the reaction time got improved to as little as 20 secs max. (under worst conditions)
- After opening the valve (by oil pressure or manually) the entire fuel system gets immediately
flood and operative.
- The only need to manually activate the valve is after fuel system had run dry and been refilled.
- Proper reaction at tipping over of equipment is guaranteed.
- Refer to operator’s handbook in case of fuel filter replacement.
- For general operating also refer to handbook and / or info-sticker. 1D_A11_E15_10.05
1 D 60 - 80 - 81 - 90

Method to define the radial play of the main bearing

When lifting the flywheel, at the indicated distance (5 mm inside

outer surface of flywheel) a play of 0.25 … 0.45 mm can be noticed.

Calculation:
o
Nominal radial play of a slide bearing is: 1...1.5/oo of the diameter
(new condition).
o
Max. after wear: 2.5 /oo (for still acceptable operation of engine)

Sample with a.m. engines:

of main bearing flywheel side:

o
60 mm x 1.5 / oo= 0.09 0.10 mm with new engine
o
60 mm x 2.5 / oo = 0.15 mm with partially-worn engine

but: point of measuring is 2.5 x the distance between main bearing

consequently:
a radial play of 0.10 x 2.5 = 0.25 mm or
0.15 x 2.5 = 0.40 mm respectively
will be measured.

Reference figures for 1 D 30...50: 0.18 … 0.30 mm

Ed. 04, 99
MSS-schi-es

1D_M03_E02_11.99
 7
Electrics
HATZ specific markings

Terminal designation as used with HATZ wiring diagrammes, and to be found o

wires as well as with engine side components

Terminal Designation

0 Ground
1 Alternator B+ (or permanent B+ connection in general)
2 3-phase generators: D+
Flywheel alternators: terminal L (white lead) in voltage regulator
3 Starter terminal 50 and other terminals in parallel
4 Oil pressure switch
5 Temperature switch on cylinder head
6 Glow plug I (if directly controlled from key switch - see “13”)
7 Solenoid for engine shut-off (hold wiring)
8 See “6”; glow plug II
9 Start-Stop input (with old version of remote start-stop)
10 Positive pole for DC motor (precision adjustment of speed)
11 Negative pole for DC motor (precision adjustment of speed)
12 Oil pressure sensor (signal output for pressure gauge)
13 Pre-glow circuit from glow timer (with A II)
14 Speed adjustment solenoid - hold winding
15 - reserved for special applications -
16 Decompression solenoid (with E 71...780 only in case of dynostarter)
17 Maintenance switch for air filter
18 Solenoid for engine shut-off (pickup winding), controlled independantly from starter
motor (see also 3.)
19 Temperature sensor on cylinder head (signal output for temp. gauge)
20 Oil temp. switch
21 Fan belt monitoring switch
22 Terminal “W” for rev.-counter or other frequency-controlled devices
(frequency output from alternator, or blue lead with SAPRISA voltage regulator)
23 Starter 30 (for connecting an ammeter)
24 Terminal C (black lead) with voltage regulators (flywheel alternators)
25 Oil temperature sensor (signal output for temp. gauge)
26 Terminal “AUS” (start signal to relay with SSM - blue lead)
27 Terminal “U 50” (black lead, start signal input from control box with SSM)
28 Speed adjustment solenoid - pickup winding
29 - reserved -

Ed. 04, 2000 Gen_13_1_E_00

MSS-schi-es
Flywheel alternators 1 D... SUPRA
Defects - Cause - Remedy
Ed. 01, 2001
Note: Prior to further tests and examination check the whole wiring system and all plugs connectorse(se
wiring MSS-schi-es
diagrams) for proper arrangement and good electrical contact
Important: Voltage regulator needs proper ground contact to engine

Charging control Battery gets over-

lamp keeps glowing
No charging of
Indication with the engine
battery charged (”boiling”
of defect running

Charging current
given No charging current

Terminal “24” (black Excessive voltage

Technical Regulator defective
(control circuit for charg.
Regulator Coils and / or magnet
lead) of regulator drop between Regulator
defective segments defective; Too large air gap
cause indic. lamp only); (charging circuit) usually the regulator not powered battery and terminal defective
charging circuit still o.k. (minimum voltage “24” of regulator
is defective as well
7 V / 14 V) *

While lead “2” of regul- Measure no load Measure the voltage bet-
Connect black
How to ator keeps grounded voltage between lead directly to ween B+ (at battery or
prove even with the engine starter motor) and end of
the yellow leads B+ lead “24”; max. diff.0,5 V
running
of coils

Replace regulator but Provide the proper Provide the proper

Replace Replace coils Adjust to Replace
engine can be operated regulator connection between connection between
Remedy even with the defect. (and/or magnet key switch “15” and nominal value key switch “15” and regulator
regulator as there is segments) terminal “24” terminal “24”
still charging current

* 7 Volt for 12 V-equipment / 14 Volt for 24 V equipment 1D_A05_E02_01.01

1 B 20 / 30 - 1 D 30...90
2 G 40 neu-new-nouveau “SAPRISA” 016 254 00
Schwungrad-Lichtmaschine / flywheel alternator /
Alternateur intégré dans le volant

Unstimmigkeiten in der Kabel-Verbindung und daraus resultierende Funktionsstörungen

Irregularities with the lead connections, and resulting functional faults
Irrégularités dans les connections de câbles et dérangements de marche résultants

Kabel-Verbindung / lead connection / Ergebnis

connection des câbles Anzeige
Result Indication
gelb schwarz weiß Résultat Indication
yellow black white
jaune noir blanc Ampere
3 ... 18
geregelt, regulated
régulation

1) 3 ... 18
geregelt, regulated
régulation

3 ... 18 max.
geregelt, regulated
régulation

rot / red / rouge 0

= verbunden - properly connected - connecté

= unterbrochen - disconnected - deconnecté

1)
gilt auch für durchgebrannte Kontrollampe / also refers to the indicator lamp bulb “burnt” /
valable aussi pour lampe témoin “grillé”

Ed. 12, 99
MSS-schi-es Gen_13_4/2_D_E_F_12.99
 1 D 60 - 80 - 81 - 90
Schwungrad-Lichtmaschine 24 V - alternator output data 24 V -
Alternateur intégré dans le volant - alternador 24 V Ed. 10, 2002
MFS-mh-es

Leerlaufspannung ge messen zwischen den beiden

gelben Kabeln der Spule (ohne Reglerschalter)
Ladestrom - charging current - No load voltage bet ween the yellowleads fromc oil
coura nt de ch arge - corrienet de carga (di sconne cted ro
f mre gulat or)
Batteries pannung 26.4 V- bat tery voltage - Mesurerl a tension de marche à v ide entre les2
tension de al batterie - tensión d e la bate ria câblesj a unesde la bobine (san s réguatl eur)
Medido la tension en vació entre los cablesam aril los
de la s bobinas (r egulador de tensión des conec tado)
U (V )
(A) High output 15A
130
15 Spule - coil 015 753 01 (TA 21)
bobine - bobina 016 395 00 (TA 22)
High output 110
Magnet ring High output
anneau magnético 015 984 02 (TA 21)
anillo magnético 016 624 00 (TA 22)
90
10

Standard Sandard
t 9A 70

Spule - coil 014 391 10 (TA 21) Standard

bobine - bobina 015 925 00 (TA 22) 50
5

Magnet ring 040 204 21 (TA 21) 30

anneau magnético 7x
anillo magnético plus
015 873 00 (TA 22) 10
0 1000 2000 3000 3600 n
1000 2000 3000 3600 n (min -1 )
(min -1)
1D_A05_D_E_F11_10.02