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
HATZ RIK TORF HS NFAB RU TORE099 MO D-94 KG

1 2 3 4
DE MA ANY RM IN GE

13 12 11 10
Operators side

5 6 7

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 13 12

15

16

17

1 2 3 4 5 6 7

11
Exhaust side

10

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
HATZ RIK TORF HS NFAB RU TORE099 MO D-94 KG

1 2 3 4
DE MA ANY RM IN GE

15 14 13 12
Operators side

5 6 7

11

10

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 13 12 11 10 9 8

15

1 2 3 4 5 6 7

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 Design Combustion air Combustion system Number of cylinders Bore / Stroke Displacement Lubricating oil capacity Difference between max and min markings Lubricating oil consumption (after running in) Lubricating oil pressure oil temperature 100 C Capacity of coolant (engine only; no radiator, no external hoses included) Direction of rotation looking at the flywheel Tappet clearance at 10 - 30 C Inlet and exhaust valve Max. admissible tilt angle during operation 2) mm max. mm cm3 approx. ltr. approx. ltr. approx. approx.

2W35

3W35 normal intake

4W35

3W35T

4W35T

Fluid-cooled four-stroke diesel engine turbo charged 4 70/90 1384 4,4 1) 1,6 1) 3 70/90 1038 3,4 1) 1,4 1) 4 70/90 1384 4,4 1) 1,6 1) Direct-injection 2 70/90 692 2,5 1) 1,2 1) 3 70/90 1038 3,4 1) 1,4 1)

0.5 % of fuel consumption at full load 3,5 bars at 3000 min-1

approx. ltr.

2,0

2,5

3,0

2,5

3,0

counter-clockwise 0,10 25 in all directions

Weight (incl. electric starter, air-cleaner and exhaust silencer) without radiator approx. kg Battery capacity

64

76

80 12V / 55 Ah

88

92

1)

2)

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. ABE /AUSF . PV CM 3 MOTOR / FABRIK NO. MIN -1 NH

MADE IN GERMANY

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

Type plate data EPA / Carb

Engine family 6 HZX L.1.38SV 2 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,...) 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

Type / Spec./ FDT 3W35 156 -2.0 Static timing (begin of fuel delivery) Customer specification (only for special equipment) Engine type

IMPORTANT ENGINE INFORMATION

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

TYPE / SPEC. / FDT SERIAL NO. MIN -1 NH / kW CM3 / PV

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 Manuf. year 1006 Year Month

1038

223

Special adjustment instruction Displacement in cm3

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 B = 502 231 01 C = 502 232 00 D = 502 233 00 E = 502 234 00 F = 502 238 00 + 502 239 00 G = 502 565 01 H = 502 825 01 J = 502 830 02 K = 503 426 00 L = 502 566 00 M = 504 851 00

Loctite Activator Loctite 574 Loctite 601 Loctite 221 Loctite 648 Technicoll 8058 Technicoll 8367 Loctite IS 407 Silicon sealer Anti-Seize compound High-temp. lub.-grease Silicon sealer Polishing paste K 240

500 ml 50 ml 50 ml 50 ml 10 ml 750 g 750 g 20 g 30 ml 1000 g 100 g 100 g 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

12

13

14

15

16

17

18

19

20

21

22

23

24

25

4 5

26

27

28

29

30 34

31
Ko st Ma x. Tra gla Eig st en 20 ge 0k w. Bj. g 20 4,5 05 kg 64 39 62 00 .00 02 .. .. .

37
ma x. 75 0k g

35

36
0,4 0,2 0,6 0,8 0 1,0

20 30

10

40

32

33

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 M 4 M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 M22 1.7 3.4 6.0 14 29 50 80 120 170 240 320 8.8 2.8 5.5 9.5 23 46 80 130 190 270 380 510 10.9 3.9 7.8 13 33 65 110 180 270 380 530 720 12.9 4.7 9.3 16 39 78 140 220 330 450 640 860

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

13515 10011

182

13.31.5

9+1

6.6+0.75

Code designations in circuit diagrams (DIN 40719)

Code A1 A2 A3 A4 B1 B2 B3 B4 C1 E1 F1 G1 G2 G3 H1 H2 H3 H4 H5 H6 H7 H8 K1 K2 K3 K4 K5 K6 K7 K8 M1 MG N1 N2 N3 N4 Designation of electrical component Equipment box Equipment panel Automatic start-stop Starter protection module Temperature sensor Speed pulse sensor Oil pressure sensor Horn Capacitor Heater for fuel filter Fuse Battery Generator (alternator) Flywheel generator 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 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 Starter motor Starter-generator 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 P1 P2 P3 R1 R2 R3 R4 R5 S1 S2 S3 S4 S5 S6 S7 S8 S9 S 10 S 11 S 12 T1 V1 V2 V3 V4 W1 W2 X1 X2 X3 X4 X5 Y1 Y2 Y3 Y4 Y5 Z1 Z2 Designation of electrical component Operating hours counter Revolution counter Pressure display Preheat glowplug Heating flange Line resistor for preheat system Resistor Line resistor with thermal time switch 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 Engine speed measurement transmitter Decoupling diode Freewheeling diode Zener diode Suppressor diode Earth (ground), negative return line Screened line at generator 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 Speed control actuating solenoid Engine shutdown actuating solenoid Servo solenoid (= valve solenoid) for engine shutdown Fuel shutoff valve High-pressure shutdown valve 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)

S1
15 H24 H0 H1 H0 H2 H17 H4 H5

A5 Instrument box

50a
START

15

012

R
H7

30

X1

22 24 1 2 3

17 4 5

18 7

N2

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

30
S8 S7

45

50
S6

G3

G
M
M1

PU

3 AW Y2

7 HW 0

Circuit diagram - Instrument box with display and flywheel alternator

G1 Engine Starting device Monitoring + Display Engine shut-down

31

Power supply / Charging device

S1

A5 Instrument box

50a
START

15

012

15 50 H2 H17 H4 H5

H24 H0

R
H7 H6

30

X1

22 24 1 2 3

17 4 5

18 7

13

N2

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

E
30
S8 S7

45

50
S6

G3

G
M
M1

PU

3 AW Y2

7 HW 0 R1

G1 Engine Starting device Monitoring + Display Engine shut-down Preheating

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

31

Power supply / Charging device

S1
15 H24 H0 H1 H0 H2 H17 H4 H5

A5 Instrument box

50a
START

15

012

R
H7

30

X1

22 24 1 2 3

17 4 5

18 7

G2

B+

30
S8 S7

45

50
S6

G
M
M1

3~

PU

3 AW Y2

7 HW 0

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

G1 31 Starting device

Engine Monitoring + Display Engine shut-down

Power supply / Charging device

S1

A5 Instrument box

50a
START

15

012

15 50 H2 H17 H4 H5

H24 H0

R
H7 H6

30

X1

22 24 1 2 3

17 4 5

18 7

13

E
30
S8 S7

G2

B+

45

50
S6

G
M
M1

3~

PU

3 AW Y2

7 HW 0 R1

G1 31 Starting device

Engine Monitoring + Display Engine shut-down Preheating

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

Power supply / Charging device

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 Shunt mode Operational mode

Y Enter.

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 stop position by pressing X.
1000 1/min 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

Procedure: learn curve is active!

Terminate calibration with Y Enter

- 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