Workshop manual

2W353W353W35T4W354W35T

Contents

Foreword

1. GeneralEngine illustrationsTechnical dataType plate dataJointing material / Sealing and bondingagentsSpecial tools and workshop equipments

2. Additional equipments

Contents

3. Basic engineReplacement of water pumpReplacement of unit injectorsAdjustment of start of deliveryReplacement of camshaft and timing chain

4.TablesInjection pump timing and injection pressureTorque wrench settingsDesignations in circuit diagramsHATZ wiring designationsElectrical circuit diagramsSealing plan for crankcase - joint face

Foreword

This Workshop Manual covers the latest technical developments according tomonth/year indicated on each page. It has been written in such a way, that it contains alldismantling and assembly instructions in accordance with the table of contents, includingall 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 ofthe necessity of carrying out such work.

Use only the tools prescribed or absolutely identical tools when carrying out work ofwhatever 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 troubleshooting 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 responsibleprofessional associations.

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

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

1. General

1 Speed adjustment lever2 Type plate3 Coolant pump4 Oil dipstick5 Oil filler cap6 Drain plug for coolant7 Oil drain plug (governor side)8 Engine mountings (optional equipment)9 Oil drain plug (operator’s side)

10 Engine oil filter11 Water drain plug on fuel filter12 Oil pressure switch13 Fuel filter with water trap14 Dry-type air cleaner15 Combustion air intake port16 Fuel suction line connector17 Fuel pre-filter

MOTORENFABRIK HATZ KG

D-94099 RUHSTORF

MADE IN GERMANY

11

17

16

15

13

12

1

2

3

4

5

6

7

810 9

14

Engine illustrations 2 W35 • 3 W35 • 4W35

Operator’s side

1 Fuel feed pump2 Fuel return line3 Stop lever (optional equipment)4 Exhaust silencer5 Exhaust gas outlet6 Electrical starter7 Central plug for electrical system8 Oil drain plug (exhaust side)9 Voltage regulator

10 Fan (optional equipment)11 Radiator (optional equipment)12 Coolant supply to engine13 Coolant return to radiator and thermostat14 Temperature switch15 Coolant expansion tank (optional

equipment)16 Vent line to expansion tank17 Cylinder head cover

1

2

3

4

5

6

7

811

14

13

12

9

15 16

10

17

Engine illustrations 2 W35 • 3 W35 • 4W35

Exhaust side

1 Speed adjustment lever2 Type plate3 Coolant pump4 Oil dipstick5 Fan (optional equipment)6 Hydraulic pump drive (optional equipment)7 Flange for additional hydraulic pump

(optional equipment)8 Oil drain plug (governor side)9 Engine mountings (optional equipment)

10 Oil drain plug (operator’s side)11 Oil filler cap12 Engine oil filter13 Water drain plug on fuel filter14 Oil pressure switch15 Fuel filter with water trap16 Dry-type air cleaner17 Combustion air intake port18 Fuel suction line connector19 Fuel pre-filter

MOTORENFABRIK HATZ KG

D-94099 RUHSTORF

MADE IN GERMANY

1

2

3

4

5

6

7

810

15

14

13

911

17

19

12

16

18

Engine illustrations 3 W35 T • 4 W35 T (turbocharged engine)

Operator’s side

1 Fuel feed pump2 Fuel return line3 Stop lever or stop solenoid

(optional equipment)4 Turbocharger5 Exhaust flange6 Electric starter7 Oil drain plug (exhaust side)8 Central plug for electrical system

9 Voltage regulator10 Coolant supply to engine11 Coolant return to radiator and thermostat12 Temperature switch13 Exhaust manifold14 Connector for vent line to expansion tank

(coolant)15 Cylinder head cover

3

4

5

6

7

1

2

12

11

10

9

8

13

14 15

Engine illustrations 3 W35 T • 4W35 T (turbocharged engine)

Exhaust side

Technical data

Type 2W35 3W35 4W35 3W35T 4W35T

Design Fluid-cooled four-stroke diesel engine

Combustion air normal intake turbo charged

Combustion system Direct-injection

Number of cylinders 2 3 4 3 4

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“ approx. ltr. 1,2 1) 1,4 1) 1,6 1) 1,4 1) 1,6 1)

markings

Lubricating oil consumption approx. 0.5 % of fuel consumption(after running in) at full load

Lubricating oil pressure approx. 3,5 bars at 3000 min-1

oil temperature 100 °C

Capacity of coolant(engine only; no radiator, approx. ltr. 2,0 2,5 3,0 2,5 3,0no external hoses included)

Direction of rotation looking at the flywheel counter-clockwise

Tappet clearance at 10 - 30 °CInlet and exhaust valve mm 0,10

Max. admissible tilt angleduring operation 2) max. 25° in all directions

Weight (incl. electric starter, air-cleaner and exhaust silencer)without radiator approx. kg 64 76 80 88 92

Battery capacity 12V / 55 Ah

1) These values are intended as an approximate guide. The max. marking on the dipstick is the determining factor.

2) Exceeding these limits causes engine breakdown.

Type plate data

MOTORENFABRIK HATZ KGD-94099 RUHSTORF

GMBH+CO

TYP KENNZ.

MOTOR/FABRIK NO. ABE/AUSF.

MIN NH PV CM

MADE IN GERMANY

-1 3

3

1) If required

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

3 W 35 T

Variation (T = Turbo)

115 12 06 001182

Type plate data EPA / Carb

6 HZX L.1.38SV 2

ENG.FAM.

TYPE / SPEC. / FDT

MIN

SERIAL NO.

NH / kW-1

MOTORENFABRIK HATZ KG·D-94099 RUHSTORF

CM3 / PV

BUILD DATE

IMPORTANT ENGINE INFORMATION

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

regulation for off-road compression-ignition engines.Refer to owner's manual

for maintenance specifications and adjustments.

VARIABLE SPEED

GMBHCO+

Made in Germany

+380 15.7 1038 223

1006

3W35 156 -2.0

2700 330

115 12 06 001182

Rated power in kWInjection pump delivery lift in mm to obtain the requiredpower output

Special adjustmentinstruction

Displacement in cm3Year

Month

Customer specification(only for specialequipment)

Engine type

Static timing(begin of fueldelivery)

V = variable speed applicationC = constant speed applicationA = V + C as well

Displacement (in cm3 or liters)Diesel engine (Benzin/gasoline = S)

Manufactorer HZX = HATZManuf. year (X = 1999, Y = 2000, 1 = 2001,...)

Type code

Speed increase underno-load condition

Nominal speed

Engine serial No.:The serial No. beginnswith 10 and changes continously if any majorchanges are carried out

Year of production

Type No.

Fabrication No.

Manuf. year

Type / Spec./ FDTEngine family

Engine speed

Engine number

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 fittingthe part refered to.See the following list for decoding the material; this list is the same as already beingused 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

Name

123456789

1011121314151617181920212223242526272829303132333435363738

638 871 00638 872 00644 735 00644 309 00642 716 00629 223 01631 392 00645 879 00641 061 00643 476 00627 500 00612 087 00644 335 00643 649 00644 327 00641 063 00644 775 00641 068 90641 050 00612 090 01626 383 00644 308 00644 374 00644 315 00626 753 91641 397 00644 342 00620 926 92634 142 00624 838 92641 610 90632 913 00624 863 02625 682 01625 751 90644 365 00643 962 00641 060 00

Disassembly tools for cable plug 2,5 mmDisassembly tools for cable plug 1,5 mmAdjusting wrench for tappet clearanceDriving device for adjustmentsPress-in tool for crankshaft seal ringValve lifting toolAssembly pin for valve stem sealControll device for unit injectorSupport to crankshaftAdjusting tool for camshaftTorx-socket TX 30 – 1/2"Dial gauge – 1/100 mmAdjusting tool for start of injectionFixing pin for speed governorSocket for start-smoke-limiterLever for coil spring to unit injectorHexagon-socket "2" for unit injectorFixation plate for cylinderPunch for closing plugPiston ring pliersPiston ring clamping tool Ø 70-100 mmTool for syncron gauge crankshaft - camshaftManometer for LDAAdapter for nozzle testerImpact extractor with accessoriesAdjusting gauge for advancerFitting device for unit cylinder - cylinderheadOil pressure gauge 0 - 6 bar with flexible tubeHoning tool 50 - 175 mmRev. meterTestbox for instrument boxHigh-pressure pump completeElevating table, mobileRevolvable fixing; basic partConsole for revolvable fixingTurning device for W35Lifting device W35Manometer for leak test

Ident-Nr.Nr.

Special tools and workshop equipments

1 6 7

16

20 25

8 9

10 11 12 13 14 15

242322

32 4 5

17 18

26 28

19

–+

21

27

1

2

3

5

6

4

0

30

#*

ON

3129

32

1020

30

40 0

0,2

0,4 0,6

0,8

1,0

38

35 36

34

max. 750 kg

33

Max. Traglast 200kg

Eigengew. 4,5 kg

Bj. 200564396200.0002Kost . . . . .

37

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 theflange faces with LOCTITE 5910.

Replacement of unit injectors

Unhook legsprings from rocker using specialtool 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 pin643 649 00 . This is the so called X - position.

Lock the control sleeve in the given position bytightening the respective screw using specialtool 644 775 00.

To remove valve rockers release lock screwand unscrew setting nut.Use special tool 644 735 00.

Remove the valve rockers

Unscrew the fuel lines for forward flow andback flow.

Remove the choke from the reverse flow con-nection nipple and unscrew the nipple.

Remove the securing clamps for the fuel pipes,using a suitable tool.

Using a screwdriver, push the fuel pipes side-ways out of the pump nozzle unit.

Release and remove the securing chamber ofthe pump nozzle unit.

Suspend the linkage for the regulating sleevefrom the regulating shaft lever.

Draw out the pump nozzle unit or release it witha suitable impact extractior .

In order to release the pump nozzle on the con-trol side, the fuel return pipe must be removed.To do this, release the clamp and draw the pipeout of the connecting element. The remainderof the dismantling procedure is as describedearlier.NOTE:Take care to ensure that no seals remain in thecylinder head.

Installing the unit injector

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

Hook the connecting rod and draw it up into thehole in the regulating sleeve.

Place the unit injector in the cylinder head andpress it in as far as the stop.

Place the retaining bar in position and tighten itslightly (pay attention to the installation posi-tion; the radius points towards the pump noz-zle).

Use the checking device 645 879 00 to ensurethe radial direction of the pump nozzle is cor-rect.

Tighten the retaining bar with a torque wrenchto 9.5 Nm.

Place the fuel delivery line in position and pushit into the unit injector as far as the stop collar.In principle, replace the O-rings and applysome grease in order for them to be fitted moreeasily.

After all the unit injectors have been fitted, in-troduce the delivery lines to a uniform depthinto each unit injector. If this is not done, the in-dividual locking elements cannot be set inplace on top.

Fix the fuel pipes in place with the securingclamps.

Always replace the sealing rings on the returnline and take care when fitting them that the se-curing ring is located in the groove.

Push the return line in as far as the stop andsecure it with clamps.

Introduce the fuel pipe into the connection nip-ple and tighten the nipple.

Subject the fuel system to 5 bar of pressure forabout 2-3 minutes with the high-pressure pump632 913 00 in order to test the sealing tightnessof the internal fuel lines.

Fit the fuel lines for delivery and return, takingcare in the process to ensure that the choke isin the correct position in the return line.

Plug the regulator unit into position with thespecial tool 643 649 00.

Release the regulator arm.

Suspend the connecting rod into the lowesthole.

Align the connecting rod at right angles to theregulating sleeve and the regulating shaft.

Press the connecting rod in the direction unitinjector, in order to compensate for any play inthe moving parts, and secure the regulatingarm.Repeat the procedure with all the pump nozzleunits.Take out the alignment pin.

Screw the blocking screw of the regulatingsleeve at the unit injectors as far as the stop.

Fit the rocker arm to the valve control. Adjustthe valve play to 0.10 mm. The valve play is ad-justed on the base circle of the camshaft. Ad-just the valve play with the adjustment nut andthen fix it with the counter-screw.

Note the correction value of the unit injector. Inthis situation, pay particular attention to thesign + or -. If there is no sign, the value is to benoted as a - value.

When fitting the rocker arm units to the unit in-jectors, make sure that the outer units are pro-vided with support for the bearing covers.

Connect the rocker arm and the pump plungerwith the securing clamp.

Lower the rocker arm in the mounting and ro-tate the eccentric shaft in such a way that theadjustment hole is pointing upwards.

Place the bearing covers in position in such away that the contact surfaces on all bearingcovers point in the same direction. Tighten thenuts by hand.

Push the rocker arm shaft in the axial directionuntil the clamps for the pump piston are locatedcentrally to the rocker arm and can be movedwithout friction resistance.

Apply preliminary tension to the bearing coverson the side with the contact surfaces as far asthe stop, and tighten the opposite side suffi-ciently for the shaft still to rotate easily.

Hook the leg spring at the bearing bolt of therocker arm into position and apply preliminarytension with the fitting tool 641 063 00.

Adjusting the start of delivery

Turn the engine over in the direction of rotationuntil the roller of the injection rocker arm is lo-cated in about the middle of the tangent.

In this position, the scaling of the flywheel is al-ready visible in the viewing hole, which is pro-vided for this cylinder. Now rotate the crank-shaft further until the specified setting value co-incides 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 takenfrom the rating plate or the injection pump setting value table.

Set the measuring gauge on the calibration de-vice to a freely chosen pre-tension value. It isrecommended that the gauge be set to threemillimetres, in order to avoid possible contactbetween the gauge and engine components.

Carefully place the measuring gauge with theprism above the roller of the rocker arm andtake care to ensure that the measuring tip is ly-ing in the dome of the cover of the pump nozzleunit. By applying slight impact movements tothe engine housing, the measuring gauge willnow oscillate to a stable value.

The first aim of the adjustment is to set thesame value in the engine as on the calibrationdevice (0 position). To do this, rotate the eccen-tric shaft with a suitable mandrel.

–+

All pump nozzle units are pre-calibrated andprovided with individual correction values. Thisvalue, in hundredths of millimetres, is engravedon the cover of the pump nozzle unit. The fig-ures express the missing stroke of the pumppiston until the suction hole begins to wear. Inthis context, pay particular attention to the sign+ or -. If there is no sign present, the value is tobe noted as a - value.

By rotating the eccentric shaft further, set themeasuring gauge in accordance with the signto the correction value.

Tighten the bearing covers with a torquewrench.Tightening torque: 9 + 1 NmIn this situation, account must be taken of thefact that the pre-set value will change again.This needs to be borne in mind when adjustingthe correction value. Deviations in the correc-tion value by +/- five hundredths of a millimetreare permissible.

Replacement of camshaft and timing chain

Unhook legsprings from rocker using specialtool 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 screwand 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 dead-centre of cylinder 1.

Unscrew the cylinder screws from thecamshaft-chain wheel.

Use tongs to draw out upwards the tensioningpin and the pin for axial securing of thecamshaft.

Secure the chain tightener with the special tool.

Remove the chain wheel and the plastictoothed wheel from the camshaft.Draw the camshaft out of the crank casing tothe rear.

Unscrew the Allen screw out of the bearingflange and remove the flange with an impactextraction tool.

Remove six Allen screws on the lower chainwheel.

Remove the axle with an impact extraction tool.

Remove the oil filling device and hydraulicpump flange respectively.

Press the chain wheel off the gear wheel.

Take out the lower chain wheel.

Draw the upper chain wheel with the controlchain upwards out of the crankcase.

Installation:

Check the flywheel marking:The engine must be stopped at the upperdead-centre of cylinder 1! Locate the gear wheel into the chain drive, inthe correct position in relation to the crankshaftgear wheel (pay attention to the marking).

Secure the chain drive gear wheel in thisposition by fitting the ancillary axle element ??? ??? ??.

Slide the camshaft into the crankcase, andlocate the plastic gear wheel on the camshaft.

Guide the camshaft chain wheel and thecontrol chain in from above.

Place the lower chain wheel in position.

Arrange the chain wheels so that they arepointing towards each other.

Place the lower chain wheel onto the gearwheel, and tighten the six Allen screws to 9.5Nm.

Place the upper chain wheel onto the camshaft, and tighten the four Allen screws (pluswasher) to 16 Nm.

Remove the ancillary axle element using theimpact extraction tool.Place the original axle element in place.

Install the bearing flange, and tighten the Allenscrew (with new sealing ring) to 23 Nm.

Insert the securing pin for securing camshaftaxial movement and fix it in position with a ten-sion pin.

Remove the special tool for the chain tightener.

Fit the closure cover so that it is flush with thecrankcase.

Fit the oil filling device and flange to the hy-draulic pump respectively.

Fit the governor unit.

Ensure that the adjustment setting elementsare correctly positioned:Regulator rod in the appropriate lever, fuel adjustment lever in the slot at the full-loadstop.

Fit the governor spring.

Adjust the governor spring in such a way that itis in contact with the deflection lever withoutany pressure.

Fit the injection timer shaft.

Check for correct seating in the control valveand in the adjustment cylinder.

Fit the rocker arm to the valve control. Adjustthe valve play to 0.10 mm. The valve play is ad-justed on the base circle of the camshaft. Ad-just the valve play with the adjustment nut andthen fix it with the counter-screw.

Note the correction value of the unit injector. Inthis situation, pay particular attention to thesign + or -. If there is no sign, the value is to benoted as a - value.

When fitting the rocker arm units to the unit in-jectors, make sure that the outer units are pro-vided with support for the bearing covers.

Connect the rocker arm and the pump plungerwith the securing clamp.

Lower the rocker arm in the mounting and ro-tate the eccentric shaft in such a way that theadjustment hole is pointing upwards.

Place the bearing covers in position in such away that the contact surfaces on all bearingcovers point in the same direction. Tighten thenuts by hand.

Push the rocker arm shaft in the axial directionuntil the clamps for the pump piston are locatedcentrally to the rocker arm and can be movedwithout friction resistance.

Apply preliminary tension to the bearing coverson the side with the contact surfaces as far asthe stop, and tighten the opposite side suffi-ciently for the shaft still to rotate easily.

Hook the leg spring at the bearing bolt of therocker arm into position and apply preliminarytension with the fitting tool 641 063 00.

In this position, the scaling of the flywheel is al-ready visible in the viewing hole, which is pro-vided for this cylinder. Now rotate the crank-shaft further until the specified setting value co-incides with the marking at the viewing hole.

Adjusting the start of delivery

Turn the engine over in the direction of rotationuntil the roller of the injection rocker arm is lo-cated in about the middle of the tangent.

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

Set the measuring gauge on the calibration de-vice to a freely chosen pre-tension value. It isrecommended that the gauge be set to threemillimetres, in order to avoid possible contactbetween the gauge and engine components.

Carefully place the measuring gauge with theprism above the roller of the rocker arm andtake care to ensure that the measuring tip is ly-ing in the dome of the cover of the pump nozzleunit. By applying slight impact movements tothe engine housing, the measuring gauge willnow oscillate to a stable value.

The first aim of the adjustment is to set thesame value in the engine as on the calibrationdevice (0 position). To do this, rotate the eccen-tric shaft with a suitable mandrel.

–+

All pump nozzle units are pre-calibrated andprovided with individual correction values. Thisvalue, in hundredths of millimetres, is engravedon the cover of the pump nozzle unit. The fig-ures express the missing stroke of the pumppiston until the suction hole begins to wear. Inthis context, pay particular attention to the sign+ or -. If there is no sign present, the value is tobe noted as a - value.

By rotating the eccentric shaft further, set themeasuring gauge in accordance with the signto the correction value.

Tighten the bearing covers with a torquewrench.Tightening torque: 9 + 1 NmIn this situation, account must be taken of thefact that the pre-set value will change again.This needs to be borne in mind when adjustingthe correction value. Deviations in the correc-tion value by +/- five hundredths of a millimetreare permissible.

4.Tables

Injection pump timing and injection pressure

Begin of delivery:

2 / 3 / 4 W35 (T) without timing device 7 [9] ° b TDC *)2 / 3 / 4 W35 (T) equipped with timing device -2 [0] ° b TDC *)

*)Value set between brackets [ ] are valid for assembly of new engines or after renewal of chaindrive!

Injection pressure: 250 + 12 bar(after a running period of approx. 100 hours) 3600 + 110 psi

8.85.8 10.9 12.9

General [Nm]:

Nm ÷ 9.81(10) = kpmNm ÷ 1.3558 = Lbs ft

Torque wrench settings

ThreadTensile quality

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

2.8

5.5

9.5

23

46

80

130

190

270

380

510

3.9

7.8

13

33

65

110

180

270

380

530

720

4.7

9.3

16

39

78

140

220

330

450

640

860

Torque wrench settings

Nm lbs ft

3.5+0.5 2.6+0.4

Nm lbs ft

9.5±1 7±0.75

21.4±1 15.8±0.75 65±5 48±3.7

16±1 11.8±0.75 5+1 3.7+0.75

27±3 20±2.2 135±15 100±11

18±2 13.3±1.5 9+1 6.6+0.75

Code designations in circuit diagrams (DIN 40719)

Code

A 1A 2A 3A 4

B 1B 2B 3B 4

C1

E1

F1

G1G2G3

H 1H 2H 3H 4H 5H 6H 7H 8

K 1K 2K 3K 4K 5K 6K 7K 8

M1MG

N 1N 2N 3N 4

Designation of electrical component

Equipment boxEquipment panelAutomatic start-stopStarter protection module

Temperature sensorSpeed pulse sensorOil pressure sensorHorn

Capacitor

Heater for fuel filter

Fuse

BatteryGenerator (alternator)Flywheel generator

Indicator lamp, generator telltaleIndicator lamp, oil pressureIndicator lamp, engine temperatureIndicator lamp, air cleaner (maintenance switch)Indicator lamp, broken beltIndicator lamp, preheat monitorIndicator lamp, fan monitorRemote display: engine on

Control relay 1 for start / start repeat interlockControl relay 2 for preheatControl relay 3 für speed controlEngine protection relayDelay relayStart interlock relayTimer relay (impulse relay)Power relay

Starter motorStarter-generator

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

Code designations in circuit diagrams (DIN 40719)

Code

P 1P 2P 3

R 1R 2R 3R 4R 5

S 1S 2S 3S 4S 5S 6S 7S 8S 9S 10S 11S 12

T1

V 1V 2V 3V 4

W 1W 2

X 1X 2X 3X 4X 5

Y 1Y 2Y 3Y 4Y 5

Z 1Z 2

Designation of electrical component

Operating hours counterRevolution counterPressure display

Preheat glowplugHeating flangeLine resistor for preheat systemResistorLine resistor with thermal time switch

Preheat starter switch (5 positions)Master switchPreheat starter switch (3 positions)Start-stop switchSpeed control switchEngine temperature switchOil pressure switchPressure switch for air cleanerFan monitoring switchPreheat temperature switchRemote start switchRemote stop switch

Engine speed measurement transmitter

Decoupling diodeFreewheeling diodeZener diodeSuppressor diode

Earth (ground), negative return lineScreened line at generator

Terminal strip on equipment boxFlat-plug distributorPlug at emergency stop switchSocket on emergency stop switchTerminal block on control box / terminal box

Speed control actuating solenoidEngine shutdown actuating solenoidServo solenoid (= valve solenoid) for engine shutdownFuel shutoff valveHigh-pressure shutdown valve

Suppressor chokeSuppressor capacitor

HATZ wiring designations

Terminal Designation0 Earth (ground)1 Generator B+2 With alternator: D+

With flywheel generator: Terminal L at regulator3 Starter terminal 504 Oil pressure switch5 Temperature switch on cylinder head6 Preheat glowplug I7 Engine shutdown solenoid8 Preheat glowplug II9 Start-stop input

10 Positive terminal for DC motor, precision speed control11 Negative terminal for DC motor, precision speed control12 Oil pressure sensor13 * * * reserved for special applications * * *14 Speed control solenoid - holding-on winding15 * * * reserved for special applications * * *16 Actuating solenoid for decompressor17 Maintenance switch for air cleaner18 Engine shutdown solenoid (energising winding)19 Temperature sensor at cylinder head20 Oil temperature switch21 Fan monitoring switch22 Terminal W for engine-speed measurement23 Starter 30 (with ammeter connection)24 Terminal C with regulator on flywheel generator25 Oil temperature sensor26 Terminal 50f at starter protection module27 * * * reserved * * *28 Speed control solenoid (energising winding)29 * * * reserved * * *

Code marking with electrical wires

"X"

"X"

"Y"

"Y"

Pin connector on wiring harness

Socket connector on engine

1 Power supply B+ (1)2 Starter motor 50 (3)A Charging lamp (2)B Oil pressure switch (4)C Temperature switch (5)D reservedE Engine shutdown solenoid (7)F reservedG reservedH Maintenance switch for air cleaner (17)J reservedK reservedL Terminal C with regulator on flywheel generator (24)M Power supply customer (24)N Ground (0)

Circuit diagram - Instrument box with display and flywheel alternator

30

MM

1

G1

U

C L B+

WG

/~ G

/~

G

N2 G3

45

177

X1

31+ –

2224

12

30

0Y

2

3 AW

7 HW

STAR

T

0 1

2

30

S1

50a

15

H24

H0

15

H17

H4H5

H2

A5

H7R

18

45S

7S

6

Pt˚

50S

8 P U

H1H0

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

G1

U

C L B+

WG

/~ G

/~

G

N2 G3

45

177

X1

S7

S6

31+ –

2224

12

30

0Y

2

3 AW

7 HW

Pt˚

0 1

2

30

S1

50a

15

H24

H0

1550

H17

H4H5

H2

A5

H7R

H6

R1

STAR

T

M130

50

M45S

8 P U

1813

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Inst

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Eng

ine

Pre

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

30

MM

1

45

177

X1

2224

12

30

0Y

2

3 AW

7 HW

STAR

T

0 1

2

30

S1

50a

15

H24

H0

15

H17

H4H5

H2

A5

H7R

18

45S

7S

6

Pt˚

50S

8 P U

H1H0

G1 31+ –

G2

B+

G U

3~W

Pow

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uppl

y / C

harg

ing

devi

ceS

tart

ing

devi

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+ D

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Inst

rum

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Eng

ine

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

G1

45

177

X1

S7

S6

31+ –

2224

12

30

0Y

2

3 AW

7 HW

Pt˚

0 1

2

30

S1

50a

15

H24

H0

1550

H17

H4H5

H2

A5

H7R

H6

R1

STAR

T

M130

50

M45S

8 P U

1813

E

G2

B+

G U

3~W

Pow

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uppl

y / C

harg

ing

devi

ceS

tart

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devi

ceM

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ring

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ut-d

own

Inst

rum

ent b

ox

Eng

ine

Pre

heat

ing