Cummins Onan HDZAA RV Generator Set Service Repair Manual

Engine Workshop Manual

RV Generator Set HDZAA

English

01−2008

983−0504 Issue 1

Workshop manual

1B30V 153..

Printed in Germany

Contents Introduction 1. General information Illustration of engine Type plate information Technical data Engine oil circuit Sealants and adhesives Special tools and workshop equipment

2. Additional equipment A 02:00 A 02.11 A 05.00 A 05.20 A 05.80

Combustion air Dry-type air cleaner Electric starting Starter Gear ring

Contents 3. Basic engine equipment M – Dismantling – cross-reference list M 01.00 Crankcase M 02.00 Crankshaft Wear and regrinding dimensions M 04.00 Camshaft and automatic decompressor M 05.00 Piston / conrod M 06.00 Cylinder M 07.00 Cylinder head M 10.00 Oil pump, regulator M 10.10 Oil pump M 10.20 Governor, speed control 1B20 up to Series 14, 1B30.10 M 10.30 Standard governor, speed control from 1B20.15, 1B30.11, 1B20V M 10.40 Generator governor, speed control from 1B20.15, 1B30.11, 1B20V on M 10.50 Governor, speed control with internal stop from 1B20.24, 1B30.19, 1B20V.14, 1B30V.11, 1B40.10 M 11.00 Timing case cover M 14.00 Fuel injection system M 14.10 Injector M 14.20 Injection pump M 14.30 Start of injection and power control M 14.31 Start of delivery and power adjustment using capillary tube M 17.00 Flywheel, generator M 26.00 Air guide M 31.00 Breather

4. Tables Start of delivery Governor components Screw tightening torques Designations in circuit diagrams HATZ wiring designations Electrical circuit diagrams

Introduction

This workshop manual represents the product’s technical status as indicated on each page (month / year). It has been compiled in such a way that any trained mechanic can perform all repairs satisfactorily. No reference is made to such work as cleaning parts etc., as it is assumed that this will always be carried out by a competent workshop when needed.

The work is to be carried out in all cases only with the specified tools or absolutely equivalent ones.

It is assumed that the mechanic has access to a full range of regular hand tools.

For maintenance work, operating fluids and other materials, troubleshooting etc., please refer to the operating manual.

Use only Original HATZ Spare Parts.

Only these guarantee the correct dimensions, ratings and quality standards.

In all relevant areas, statutory requirements and the regulations issued by authorised trade associations and industrial accident insurers are applicable.

The details supplied here may vary if special equipment is incorporated; such deviations cannot be taken into account in the workshop manual or in the spare parts list.

If any difficulties arise, please contact the nearest HATZ Service point.

1. General information

1B . . / 06.07

1

Illustration of engine

1 2 3 4 5 6 7 8

1

Tank cover Recoil starter Dry-type air cleaner Intake opening for cooling and combustion air Voltage regulator Electric starter Noise insulating hood Tightening strap (concealed by noise insulating hood)

1B . . / 06.07

9 10 11 12 13 14 15 16

Shutdown pin Speed control lever Oil filter Oil drain plug Oil filler and dipstick Exhaust screen Silencer (exhaust) Type plate

EPA / CARB - type plates

Engine family

Type / Spec./ FDT

4 HZX L.232 V 20

1B20-7 199D 14.0 Type code

V = variable speed application C = constant speed application A = V + C as well Displacement (in cm3 or liters) Diesel engine (Benzin/gasoline = S) Manufactorer HZX = HATZ Manuf. year (X = 1999, Y = 2000, 1 = 2001,...)

Static timing (begin of fuel delivery) Customer specification (only for special equipment) Variation Engine type

Engine number 100 28 04 063750 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 2650

310

IMPORTANT ENGINE INFORMATION + CO KG·D-94099 RUHSTORF MOTORENFABRIK HATZ GMBH ENG.FAM.

TYPE / SPEC. / FDT CM3 / PV

SERIAL NO. MIN -1

NH / kW

BUILD DATE

Made in Germany VARIABLE SPEED This engine conforms to MY U.S. EPA regulations large nonroad compression-ignition engines and MY California regulation for off-road compression-ignition engines.

Refer to owner's manual for maintenance specifications and adjustments.

Speed increase under no-load condition Nominal speed

6.2

2.8 Rated power in kW Injection pump delivery lift in mm to obtain the required power output

0232

245

Special adjustment instruction Displacement in cm3

Manuf. year 0504 Year Month

1B . . / 06.07

1

Technical data Type

1 B 20

Description

1 B 30

air-cooled four-stroke diesel

Fuel supply/combustion system

direct injection

Number of cylinders

1

1

Bore / stroke

mm

69 / 62

80 / 69

Displacement

cc

232

347

1:21.0

1:21.0

Compression ratio Max. lubricating oil content

app. l

0.9*

1.1*

Amount of oil between “max” und “min” marks

app. l

0.5*

0.5*

Engine oil consumption (after running in for approx. 50 hours) Engine oil pressure at oil temperature 100 °C

max.

1 % of full-load fuel consumption

app.

2.5 bar at 3000 rpm

Direction of rotation (power take-off end)

counter-clockwise

Weight (incl. tank, air cleaner, silencer, recoil starter and electric starter)

app. kg

33

38

Cooling air requirement at n = 3000 rpm

m3 / min

4.5

6.3

Combustion air requirement at n = 3000 rpm m3 / min

0.35

0.52

Max. continuous operating angle – with flywheel end lower – in other directions

25° 35°

Starter

12 V - 0.8 kW

Generator charging current at 3000/1500 rpm Battery

12 V - 14 A / 6.5 A min/max

* These values are to be understood as approximate.

Always refer to the max. mark on the dipstick.

1

1B . . / 06.07

12 V - 36 / 60 Ah

Technical data Type

1 B 40

Description

1 B 50

air-cooled four-stroke diesel

Fuel supply/combustion system

direct injection

Number of cylinders

1

1

Bore / stroke

mm

88 / 76

93 / 76

Displacement

cc

462

517

1:20.5

1:20.5

Compression ratio Max. lubricating oil content

app. l

1.5*

1.5*

Amount of oil between “max” und “min” marks

app. l

0.8*

0.8*

Engine oil consumption (after running in for approx. 50 hours)

max.

1 % of full-load fuel consumption

Engine oil pressure at oil temperature 100 °C

app.

2.5 bar at 3000 rpm

Direction of rotation (power take-off end)

counter-clockwise

Weight (incl. tank, air cleaner, silencer, recoil starter and electric starter)

app. kg

55

55

Cooling air requirement at n = 3000 rpm

m3 / min

8.7

8.7

Combustion air requirement at n = 3000 rpm m3 / min

0.69

0.78

Max. continuous operating angle – with flywheel end lower – in other directions

25° 35°

Starter

12 V - 0.8 kW

Generator charging current at 3000/1500 rpm Battery

12 V - 14 A / 6.5 A min/max

12 V - 36 / 60 Ah

* These values are to be understood as approximate.

Always refer to the max. mark on the dipstick.

1B . . / 06.07

1

Engine oil circuit

1

8

2 3 4 5

6 7

1 2 3 4

1

Oil pressure switch Camshaft bearing, timing end Oil pump Camshaft bearing, flywheel end

1B . . / 06.07

5 6 7 8

Main and big-end bearings (crankshhaft) Intake screen Oil mesh filter Gap between crankcase and cylinder liner (for heat dissipation)

Sealants and adhesives Use of sealants and adhesives: Code letters on the drawings refer to the materials listed below. The same details appear in our spare parts lists.

A = 502 230 01

Loctite Activator

500 ml

B = 502 231 00

Loctite 573

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

30 ml

J = 502 830 02

High-temperature paste

K = 503 426 00

High-temperature grease

100 g

L = 502 566 00

Silicon

100 g

M = 504 851 00

Grinding paste K 240

1000 g

80 ml

1B . . / 06.07

1

Special tools and workshop equipment Series 1 B .. engines

No.

Ident. No.

Designation

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

629 635 626 644 630 643 631 612 626 624 642 641 630 620 643 643 643 634 624 639 632 624 625 625 631

Valve lifting tool Holder to prevent flywheel movement Driving-out tool with accessories Cable plug removal tool Allen socket 6 mm lg 1/2" Assembly pin for injection pump Assembly pin for valve stem seal Piston ring pliers Piston ring compressing tool Crimping pliers Capillary tube Testbox Test nozzle, 400 bar Oil pressure gauge, 0...6 bar with flexible hose Socket for PTO shaft - 30 mm Socket for PTO shaft - 27 mm Socket for PTO shaft - 24 mm Honing tool Revolution counter Support for photo-sensor 1B High-pressure pump, complete Hydraulic lift trolley Console for revolvable fixing Revolvable fixing - basic part Revolvable fixing - adaptor engine side

1

223 389 753 345 815 982 392 090 383 845 707 610 094 926 979 980 981 142 838 123 913 863 751 682 300

1B . . / 10.04

01 90 91 90 00 00 00 01 00 01 00 90 90 92 00 00 00 00 92 00 00 02 90 01 00

Special tools and workshop equipment

2

1

4

3

10

9

8

3

5

6

11

12

7

4 5

2

1

6

0

13

15

18

17

16

O N

#

*

14

20

22

10

30 40

ma

19

x.

75

0k

g

21

20

24 23

25 1B . . / 10.04

1

2. Additional equipment

1B . . / 06.07

2

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