Hatz 3m41 мануал на русском

Contents

3

Table of Contents

4

General Information

7

Engine Illustrations

8

Governor and Exhaust Side View

8

Service and Flywheel Side View

8

Starter and Flywheel Side View

8

Encapsulated Design

9

Operating and Flywheel Side View

9

Operating and Governor Side View

9

Outgoing Air and Flywheel Side View

9

Engine Flywheel Side View

10

Engine Operating Side View

10

Governor — and Exhaust Side View

11

Type Plate Data

12

Lubricating Oil Circuit

13

Technical Data L 30

14

Technical Data L 31, M 31, L 40, M 40

15

Technical Data L 41, M 41

16

Sealants and Adhesives

17

Series L / M Engines

18

Special Tools and Workshop Equipment

18

Additional Equipment

23

Fuel

24

Fuel Delivery Pump Dismantling/Assembling

24

Exhausts

25

Removing and Installing the Muffler Enclosure (L 30, L 31, L 40, C/K)

25

Crank Handle Inspection/Repair

27

Start Mechanical

27

Handle with Kick-Back Damping Demontage

28

Handle with Kick-Back Damping Assembling

29

Handle with Kick-Back Damping Inspection/Repair

29

Automatic Decompressor (M 31, M 40, M 41)

30

Recoil Starter

33

Start Release Device (L /M 31/40/41)

34

Start Electrical

36

Checking Operation of the Alternator with Voltage Regulator

36

General Instructions on the Engine’s Electrical System

36

Alternator (Air-Cooled Engines)

37

Notes on Renewing the Alternator

38

Lubricating Oil

39

Oil Cooler (Air-Cooled Engines)

39

Oil Cooler (Water-Cooled Engines)

40

Automatic Devices

41

Engine Shutdown Solenoid

41

Adjusting Engine Shutdown and Solenoid

42

Installing the Shutdown Device

42

Temperature-Controlled Starting Fuel Volume Control

43

Connecting Housing

44

Liquid Cooling

45

Water Pump (H.L 30)

45

Thermostat (H.L 30)

46

Basic Engine Equipment

47

• Crankcase

  48

• Removing and Installing Balancing Weights — 2L / 3L

  48

• Removing and Installing Balancing Weights — 4 L

  50

1000 M 01.00 Crankshaft

54

• Cleaning the Crankcase, Installing the Oil Spray Jets

  54

• M 01.30 Cleaning Crankcase

  54

M 02.00 Crankshaft

56

• Camshaft, Valve Gear

  62

M 04.00 Camshaft

62

• M 04.20 Camshaft for Injection Pump

  65

  • Attaching the Intermediate Gearwheel

    66

  • Installing the Camshaft

    66

• M 04.30 Governor and Injection Timer

  67

M 05.00 Conrod

71

M 06.00 Piston and Cylinder

72

• M 06.10 Air-Cooled Engines

  72

• Water-Cooled Engines (H.L 30)

  74

• M 06.20 Water-Cooled Engines

  74

M 07.00 Cylinder Head

77

• M 07.10 Air-Cooled Engines

  77

  • Overhauling Cylinder Head (Air-Cooled Engines)

    81

  • Assembling Cylinder Head

    82

  • Cylinder Head — Water-Cooled Engines (H.L 30)

    84

• M 07.30 Water-Cooled Engines

  84

• Reconditioning the Cylinder Head (Water-Cooled Engines)

  86

M 10.00 Oil Pump

89

• Checking Oil Pressure

  90

• Timing Cover

  91

• Timing Cover for Hydraulic Pump Drive

  92

1000 M 12.00 Starting Charge

94

1000 M 11.00 Timing Case Cover

94

• Extra-Fuel Device

  94

• M 12.10 with Injection Pump PFR 1K 80

  94

• M 12.20 with Injection Pump PFR 1K 90

  96

• Adjusting the Engine Monitoring Block

  97

• M 12.30 with PFR 1K 90 Injection Pump

  98

• Dismantling the Servo Block

  99

• Servo Block Inspection/Repair

  99

• Assembling the Servo Block

  99

• Checking Valve Solenoid

  100

M 13.00 Fan

101

• Injection Pump, Functional Check

  102

M 14.00 Fuel Injection Equipment

102

• M 14.10 with Injection Pump PFR 1K 80

  103

• Removing the Injection Pump

  103

• Removing the Governor Rod

  103

• Installing the Governor Rod

  104

• M 14.20 with Injection Pump PFR 1K 90

  106

• M 14.30 Injector

  108

• M 14.40 Injector Nozzle

  110

  • Adjustment Work with PFR 1K 80 Injection Pump

    111

  • Adjusting Start of Fuel Delivery

    112

  • Adjusting End of Fuel Delivery

    114

  • Synchronising Injection Pump Delivery Volume

    114

  • Adjusting Effective Stroke (on Engines W/Start of Delivery Adjustment)

    115

  • Adjusting Effective Stroke (on Engines W/End-Of-Delivery Adjustment)

    116

  • Note on Changing the Power Setting

    116

  • Adjustment Work with PFR 1K 90 Injection Pumps

    117

  • Crankcase Mark for Adjusting Start of Fuel Delivery

    118

  • Marking the Crankcase for the Radial Position of the Injection Pumps

    119

  • Adjusting Injection Volume for Nominal Power Output (Engine Stopped)

    119

  • Adjusting the Damping Spring (Generator Operation, PV 187)

    121

  • Schwungrad

    122

1000 M 17.00 Flywheel

123

• Engine Shutdown Device / Belt Tensioner

  123

M 20.00 Engine Shutdown Device

123

M 22.00 Air Cleaner

126

M 31.00 Crankcase Breather

127

• Engines with PFR 1K 80 Injection Pump

  128

M 32.00 Speed Control

128

• Engines with PFR 1K 90 Injection Pump

  130

• Capsule

  132

Tables

135

• Tightening Torques for Threaded Connections

  136

• Tightening Torques in Nm

  137

• Repair Data

  138

  • Cylinder Head Data

    138

  • Camshaft Bearing Journal Diameters

    140

  • Internal Diameter of Bearing Bore in Crankcase

    140

  • Balancing Weights

    141

  • Bearing Point Diameters – Two- and Three-Cylinder Engines

    141

  • Bearing Point Diameters — Four Cylinder Engines

    141

  • Conrod Data

    142

  • Cylinder Data

    142

  • Piston Data

    142

  • Piston Rings Data

    143

  • Crankshaft Data

    144

  • Fuel Injection Equipment Data

    146

  • Injectors Data

    146

  • Governors Data

    147

  • Lubricating Oil Content and Dipstick

    148

  • Key to Circuit Diagrams (DIN 40719)

    149

  • HATZ — Wiring Identification

    151

  • Circuit Diagram 12 V — System with Fault Display

    152

  • Diagram 12 V: System with Fault Display/Starter Protection Module

    153

  • Diagram 12 V: System with Auto Shut down and Starter Protection Module

    154

  • Circuit Diagram 12 V — System with Automat. Shut down and Time Relay

    155

  • Diagram 12 V: Automatic Start/Stop W/Repeat Start Interlock/Time Relay

    156

  • Circuit Diagram 24 V — System with Fault Display

    157

  • Diagram 24 V — System with Fault Display and Starter Protection Module

    158

  • Diagram 24 V: System with Auto Shut down and Starter Protection Module

    159

  • Circuit Diagram 24 V — System with Automat. Shut down and Time Relay

    160

  • Diagram 24 V: Start/Stop with Repeat Start Interlock and Time Relay

    161

  • Troubleshooting Table for Electrical System

    162

  • Troubleshooting at Instrument Box

    162

  • Troubleshooting at the Battery

    163

  • Troubleshooting at the Starting Device

    167

  • Troubleshooting at the Pre-Heat System

    170

  • Troubleshooting at the Alternator

    171

  • Troubleshooting at Engine Monitor and Display

    173

  • Troubleshooting at Electromagnetic Components

    174

Table of Contents

3

1 Notices

5

2 General Information

6

3 Safety

7

• General Information

  7

• Intended Use and Foreseeable Misuse

  7

• Machine User or Machine Manufacturer Obligations

  8

• Representation of Safety Notes

  9

• Meaning of Safety Symbols

  10

• Safety Notes

  12

• Operational Safety

  12

• Machine-Specific Safety Instructions for Operation

  15

• Machine-Specific Safety Instructions for Maintenance Work

  16

• Electrical Equipment

  18

• Labels

  20

4 Technical Data

21

• Engine Information and Filling Quantities

  21

• Engine Type Plate

  23

• Physical Operating Conditions

  24

• Engine Oil

  24

• Fuel

  25

5 Engine Design

27

6 Transport, Assembly and Commissioning

33

• Transport

  33

• Installation Notes

  34

• Preparations for Commissioning

  35

• Filling Engine Oil (First Filling)

  35

7 Operation and Use

37

• Safety Notes

  37

• Performing Tests

  38

• Start Preparation

  38

• Pumping Fuel with the Manual Lever

  38

• Pumping Fuel with the Manual Fuel Pump

  39

• Setting the Speed Control

  41

• Starting the Engine

  45

• Starting the Engine with a Starter

  48

• Switching off the Engine

  52

• Switching off the Engine (Mechanical)

  53

• Switching off the Engine (Electrical)

  54

• Refueling

  55

• Checking the Water Separator

  56

• Check the Oil Level

  57

8 Maintenance

59

• General Maintenance Instructions

  59

• Maintenance Work

  60

• Maintenance Notice Label

  60

• Maintenance Plan

  62

• Checking the Intake Area of the Combustion Air

  63

• Checking the Cooling Air Area

  63

• Change the Engine Oil

  68

• Checking the Poly V Belt

  70

• Cleaning the Cooling Fan, Cooling Fins and Oil Cooler

  72

• Checking the Screw Connections

  75

• Cleaning the Screen Insert in the Exhaust Pipe (Additional Equipment)

  75

• Changing the Fuel Prefilter

  77

• Maintaining the Dry Air Filter

  79

• Checking and Cleaning the Air Filter Cartridge

  81

• Check and Set the Tappet Clearance

  83

• Changing the Oil Filter

  86

• Change the Main Fuel Filter

  87

• Checking that the Air Filter Maintenance Indicator Is Working Properly

  91

• Renewing the Poly V Belt and Checking the Function of the Switch-Off Unit

  93

9 Faults

97

• Trouble Shooting

  97

• Emergency Start

  102

10 Storage and Disposal

105

• Storing the Machine

  105

• Disposing of the Machine

  107

11 Installation Declaration

108

12 Declaration of the Manufacturer

109

Table of Contents

3

1 Important Notes on Safe Operation of the Engine

4

2 Description of Engine

6

3 General Information

10

• Technical Data

  10

• Transport

  11

• Load on Engine

  11

• EPA/CARB-Type Plates and Fuel Label

  11

• Emission-Related Installation Instructions

  12

4 Operation

13

• Starting the Engine

  18

• Stopping the Engine

  21

5 Maintenance

22

• Maintenance Summary

  22

• Maintenance Every 8 — 15 Hours of Operation

  25

• Maintenance Every 250 Hours of Operation

  27

• Maintenance Every 500 Hours of Operation

  31

• Maintenance Every 1000 Hours of Operation

  31

6 Operating Checks and Repair Work

38

• Checking Operation of Air Cleaner Maintenance Indicator

  38

• Renewing Fan Drive Belt, Checking Operation of Belt Monitor

  40

7 Malfunctions — Causes and Remedies

42

8 Work on the Electrical System

46

9 Protective Treatment

46

Supplemental Information to the Owner’s Manual for 2008 and Later

48

Table of Contents

3

1 Important Notes on Safe Operation of the Engine

4

2 Description of Engine

6

3 General Information

10

• Technical Data

  10

• Transport

  11

• Installation Instructions

  11

• Load on Engine

  11

• Type Plate

  11

4 Operation

12

• Before Initial Start-Up

  12

• Engine Oil

  12

• Fuel

  13

• Starting the Engine

  14

• Starting with the Electric Starter

  15

• Emergency Starting

  17

• Starting with Handle

  17

• Starting with the Handle with Kick-Back Damping

  19

• Stopping the Engine

  20

5 Maintenance

21

• Maintenance Summary

  21

• Maintenance Every

  24

• Hours of Operation

  24

• Check Engine Oil Level

  24

• Check Combustion Air Intake Area

  24

• Check the Cooling Air System

  26

• Maintenance Every 250 Hours of Operation

  26

• Engine Oil Change

  26

• Cleaning Cooling Fan, Cooling Fins and Oil Cooler

  27

• Checking Threaded Connections

  29

• Cleaning of Mesh Insert in Exhaust Pipe

  29

• Check Water Trap

  30

• Maintenance Every 500 Hours of Operation

  30

• Replace Fuel Pre-Filter

  30

• Air Cleaner Maintenance

  31

• Checking and Adjusting Valve Clearances

  34

• Engine Oil Change

  35

• Renewing Oil Filter

  35

• Maintenance Every 1000 Hours of Operation

  36

• Renewing the Fuel Filter

  36

6 Operating Checks and Repair Work

38

• Checking Operation of Air Cleaner Maintenance Indicator

  38

• Renewing Fan Drive Belt, Checking Operation of Belt Monitor

  39

7 Malfunctions — Causes and Remedies

42

8 Work on the Electrical System

46

9 Protective Treatment

46

Table of Contents

3

1 Important Notes on Safe Operation of the Engine

4

2 Description of Engine

6

3 General Information

8

• Technical Data

  8

• Transport

  9

• Load on Engine

  9

• Type Plate

  9

4 Operation

9

• Starting the Engine

  12

• Stopping the Engine

  14

5 Maintenance

15

• Maintenance Summary

  15

• Maintenance Every 8 — 15 Hours of Operation

  18

• Maintenance Every 250 Hours of Operation

  18

• Maintenance Every 500 Hours of Operation

  20

• Maintenance Every 1000 Hours of Operation

  23

6 Operating Checks and Repair Work

24

• Checking Operation of Air Cleaner Maintenance Indicator

  24

• Renewing Fan Drive Belt, Checking Operation of Belt Monitor

  24

7 Malfunctions — Causes and Remedies

26

8 Work on the Electrical System

30

9 Protective Treatment

30