Page 1
CRE ATI NG POW ER SOL UTI ONS .
1B20 | 1B27 | 1B30 | 1B40 | 1B50
OPERATOR'S MANUAL
Diesel engine
Hatz Diesel
www.HATZ-DIESEL.com
Page 2
Page 3
1B20, 1B27, 1B30, 1B40, 1B50 Table of contents
Table of contents
1 Notices .................................................................................................................5
2 General information ............................................................................................ 6
3 Safety ................................................................................................................... 7
3.1 General information............................................................................................... 7
3.1.1 Intended use and foreseeable misuse .................................................................. 7
3.1.2 Machine user or machine manufacturer obligations ............................................. 8
3.1.3 Representation of safety notes ............................................................................. 9
3.1.4 Meaning of safety symbols.................................................................................. 10
3.2 Safety notes ........................................................................................................ 12
3.2.1 Operational safety ............................................................................................... 12
3.2.2 Machine-specific safety instructions for operation .............................................. 15
3.2.3 Machine-specific safety instructions for maintenance work ................................ 16
3.2.4 Electrical equipment............................................................................................ 18
3.3 Labels.................................................................................................................. 20
4 Technical data ................................................................................................... 22
4.1 Engine information and filling quantities.............................................................. 22
4.2 Engine type plate ................................................................................................ 23
4.3 Physical operating conditions.............................................................................. 24
4.4 Engine oil ............................................................................................................ 25
4.5 Fuel .....................................................................................................................26
5 Engine design.................................................................................................... 27
6 Transport, assembly and commissioning ...................................................... 29
6.1 Transport............................................................................................................. 29
6.2 Installation notes ................................................................................................. 30
6.3 Preparations for commissioning.......................................................................... 31
6.4 Filling engine oil (first filling) ................................................................................ 32
6.5 Filling the oil bath air filter (option) ...................................................................... 33
7 Operation and use............................................................................................. 34
7.1 Safety notes ........................................................................................................ 34
7.2 Performing tests .................................................................................................. 35
7.3 Setting the speed control .................................................................................... 36
7.4 Starting the engine .............................................................................................. 37
7.4.1 Starting the engine with recoil start (up to -6 °C) ................................................ 38
7.4.2 Starting the engine with a starter ........................................................................ 39
7.5 Switching off the engine ...................................................................................... 43
7.5.1 Switching off the engine (mechanical) ................................................................ 43
7.5.2 Switching off the engine (electrical) .................................................................... 45
7.6 Checking the oil level and adding oil if necessary............................................... 47
7.6.1 Engine oil level .................................................................................................... 48
7.6.2 Oil level in the oil bath filter (option) .................................................................... 49
HATZ
3Operator's Manual
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Table of contents 1B20, 1B27, 1B30, 1B40, 1B50
7.7 Refueling ............................................................................................................. 50
7.8 Checking the water separator ............................................................................. 52
7.9 Check the air filter warning indicator (option)...................................................... 54
8 Maintenance ...................................................................................................... 55
8.1 General maintenance instructions....................................................................... 55
8.2 Maintenance work ............................................................................................... 56
8.2.1 Maintenance notice label .................................................................................... 56
8.2.2 Maintenance plan................................................................................................ 57
8.2.3 Checking the intake area .................................................................................... 59
8.2.4 Change the engine oil ......................................................................................... 60
8.2.5 Clean the oil filter ................................................................................................ 62
8.2.6 Check and set the tappet clearance.................................................................... 65
8.2.7 Maintaining the oil bath filter ............................................................................... 68
8.2.8 Clean the cooling air area ................................................................................... 70
8.2.9 Check the screw connections ............................................................................. 73
8.2.10 Clean the exhaust screen ................................................................................... 73
8.2.11 Changing the fuel filter ........................................................................................ 78
8.2.12 Maintaining the dry air filter ................................................................................. 83
8.2.13 Checking and cleaning the air filter cartridge ...................................................... 84
9 Faults.................................................................................................................. 86
9.1 Troubleshooting .................................................................................................. 86
9.2 Emergency start .................................................................................................. 91
10 Storage and disposal........................................................................................ 93
10.1 Storing the machine ............................................................................................ 93
10.2 Disposing of the machine.................................................................................... 95
11 Installation declaration ..................................................................................... 96
4
Operator's Manual
HATZ
Page 5
1B20, 1B27, 1B30, 1B40, 1B50 Notices
1 Notices
Contact data
© 2016
Motorenfabrik HATZ
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. +49 (0)8531 319-0
Fax +49 (0)8531 319-418
marketing@hatz-diesel.de
www.hatz-diesel.com
All rights reserved!
Copyright
The copyright for this Operator's Manual rests entirely with Motorenfabrik
HATZ, Ruhstorf.
This Operator's Manual may only be copied or distributed if written approval
has been received. This also applies to the copying or distribution of excerpts of the Operator's Manual. The same conditions apply to distribution of
the Operator's Manual to third parties in digital form.
Original Operator's Manual
This Operator's Manual was translated into multiple languages.
The German version is the original Operator's Manual. All other language
versions are translations of the original Operator's Manual.
HATZ
5Operator's Manual
Page 6
General information 1B20, 1B27, 1B30, 1B40, 1B50
2 General information
Information on the document
This Operator's Manual was created with due care. It is exclusively intended
to offer a technical description of the machine and to provide instructions on
commissioning, operating and maintaining the machine. When operating the
machine, the applicable standards and legal regulations as well as any inhouse regulations apply.
Before commissioning, during operation and before maintenance work is begun on the machine, read the Operator's Manual carefully and keep it close
by for ready access.
Machine
This Operator's Manual describes the following machine.
Machine name HATZ diesel engine
Type number 1B20, 1B27, 1B30, 1B40, 1B50
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the over 500 HATZ service stations. Trained specialists there will repair your machine with Hatz original spare parts and
with HATZ tools. The global HATZ service network is at your disposal to advise you and supply you with spare parts. For the address of the Hatz ser-
vice station nearest you, please see the directory included or visit the internet at: www.hatz-diesel.com
Problems may occur if unsuitable spare parts have been installed. We cannot accept responsibility for damage and secondary damage that result from
this.
We therefore recommend the use of genuine Hatz original spare parts.
These parts are manufactured according to strict Hatz specifications and
achieve maximum operational reliability through their perfect fit and functionality. The order number can be found in the enclosed spare parts list or on
the internet at: www.hatz-diesel.com
Exclusion of liability
The manufacturer cannot be held responsible for personal injury, damage to
property, or damage to the machine itself caused by improper use, foreseeable misuse, or failure to follow or adequately follow the safety measures
and procedures described in this Operators Manual. This also applies to
changes made to the machine and the use of unsuitable spare parts.
Modifications, which serve technical improvement, are reserved.
6
Operator's Manual
HATZ
Page 7
1B20, 1B27, 1B30, 1B40, 1B50 Safety
3 Safety
3.1 General information
Introduction
This chapter contains the information you need to work safely with this machine.
To prevent accidents and damage to the machine, it is imperative that these
safety instructions be followed.
Read this chapter carefully before beginning work.
3.1.1 Intended use and foreseeable misuse
Intended use
The machine described in this Operator's Manual fulfills the following functions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See chapter 11 Installation declaration,
page 96.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine into which the engine is installed.
Any other use is not intended and therefore not permitted. Violations compromise the safety of the personnel working with the machine. Responsibility
is not accepted by Motorenfabrik HATZ for damage resulting from this situation.
The operational safety of the machine is only guaranteed if it is used as intended.
Use according to the intended purpose also includes observance of the instructions in this Operator's Manual.
HATZ
Foreseeable misuse
The following is considered to be foreseeable misuse:
▪ Any use that varies from or extends beyond the uses specified above.
▪ Failure to comply with the instructions in this Operator's Manual.
▪ Failure to comply with the safety instructions.
▪ Failure to immediately eliminate malfunctions that impact safety before
continuing work with the machine (working with the machine when it is not
in perfect condition, either functionally or in terms of safety).
▪ Failure to perform the necessary inspection and maintenance work.
▪ Any unauthorized modification of or removal of safety equipment.
▪ Use of spare parts and accessories that are unsuitable or have not been
approved by HATZ.
▪ Operation in flammable or hazardous environments.
7Operator's Manual
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Safety 1B20, 1B27, 1B30, 1B40, 1B50
▪ Operation in closed-off or poorly ventilated rooms.
▪ Installation of the machine in moving equipment (e.g. vehicles, trailers) or
in closed rooms without additional measures to handle supply air, extract
air, and exhaust gas.
▪ Improper operation at variance with DIN 6271 and DIN ISO 8528 (climate,
load, safety).
Residual risks
Residual risks result during daily use and in association with maintenance
work.
These residual risks will be pointed out in chapter 3.2.2 Machine-specific
safety instructions for operation, page 15 and in chapter 3.2.3 Machinespecific safety instructions for maintenance work, page 16 as well as in the
further contents of the manual, directly in front of the descriptions or Operating Instructions concerned.
3.1.2 Machine user or machine manufacturer obligations
Machine manufacturer obligations
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine. These assembly instructions contain important information on how to safely install the engine and are available at your nearest HATZ service station.
It is prohibited to start the engine before it is fully installed.
In addition, please note that it is prohibited to start up the machine before it
has been determined that the machine into which this engine is installed fulfills all safety-related requirements and legal regulations.
User obligations
The user is obliged to operate the machine when it is in perfect condition
only. The user must check the condition of the machine before use and ensure that any defects are eliminated before it is taken into service. Running
the machine while identified defects exist is not permitted. The user must
also ensure that all persons who work on the machine are familiar with the
contents of this Operators Manual.
8
Operator's Manual
HATZ
Page 9
1B20, 1B27, 1B30, 1B40, 1B50 Safety
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood the Operator's Manual or must possess the qualifications necessary for working with this equipment, acquired in training/instructional courses. No one may work with the machine without the necessary
qualifications, even if for just a brief period.
The operating personnel must not be under the influence of drugs, medication or alcohol.
All work performed on the machine must be in compliance with the information provided in the Operator's Manual.
Storing the Operator's Manual
This Operator's Manual is an integral component of the machine (also when
being sold). It must be stored in the direct vicinity of the machine and be accessible to personnel at all times.
3.1.3 Representation of safety notes
Overview
This machine has been designed and built according to state-of-the-art technology and the recognized safety standards. Despite these precautions,
risks exist when operating the machine and during maintenance work.
These risks are identified in this manual by means of safety notes.
The safety notes precede the related description or operating step.
HATZ
Structure of the safety notes
The safety notes consist of:
▪ Danger symbol
▪ signal word
▪ Description of danger
▪ Possible consequences
▪ Preventative measures
General danger symbol
The general danger symbol is used to identify the danger of personal injury.
9Operator's Manual
Page 10
Safety 1B20, 1B27, 1B30, 1B40, 1B50
DANGER
WARNING
CAUTION
CAUTION
NOTICE
Signal words
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
Danger symbol/
signal word
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this Operator's Manual.
Symbol Meaning
Smoking, fire, and open flames are prohibited!
Meaning
This signal word is used to indicate imminently
dangerous situations which, if not avoided, will
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to minor or moderate injury.
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
This signal word indicates additional useful information, such as operating tips and cross references.
10
Warning of personal injury!
Warning of hot surfaces!
Warning of flammable substances!
Operator's Manual
HATZ
Page 11
1B20, 1B27, 1B30, 1B40, 1B50 Safety
i
Symbol Meaning
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
Warning of heavy loads!
Warning of environmental damage!
Comply with the Operator's Manual or additional documentation from other manufacturers or the user!
HATZ
Additional information that is useful to the reader.
11Operator's Manual
Page 12
Safety 1B20, 1B27, 1B30, 1B40, 1B50
3.2 Safety notes
3.2.1 Operational safety
Introduction
This chapter contains all of the important safety instructions for personal protection and for safe and reliable operation. Additional, task-related safety instructions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury or danger of property damage due to failure to comply with the Operator's Manual and
the safety instructions contained therein.
▪ As the user of the machine, you must ensure that all people
working on the machine are familiar with the content of this
Operator's Manual.
▪ Before working on the machine, read this Operator's Manual
carefully, paying special attention to the safety notes.
▪ Fulfill all required safety conditions before working on the
machine.
▪ Follow all general safety instructions as well as the specific
task-related safety instructions contained in the individual
chapters.
12
Using the machine
▪ Only operate the machine for the purposes described in chapter 3.1.1 In-
tended use and foreseeable misuse, page 7.
Compliance with other regulations
▪ Adhere to the applicable accident prevention regulations of the trade asso-
ciations.
▪ Comply with the regulations concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regula-
tions also apply when operating the machine.
Personal protective equipment
During operation and maintenance of the machine, personal protective
equipment must be available and must be used if necessary. The required
personal protective equipment is specified in the descriptions of the operating steps.
Operator's Manual
HATZ
Page 13
1B20, 1B27, 1B30, 1B40, 1B50 Safety
Personal protective
Pictogram Function
equipment
Safety shoes Safety shoes offer protection
against:
▪ Slipping
▪ Falling objects
Hearing protection Hearing protection offers protec-
tion against ear injuries due to
excessive and constant noise.
Safety gloves Safety gloves protect the hands
against injury, e.g. from battery
acid.
Safety goggles
(with side protection)
Safety goggles protect the eyes
from flying objects (e.g. dust
particles, spraying liquids, spraying acid).
Working clothes Wear close-fitting clothing. How-
ever, it must not restrict the
wearer's freedom of movement.
Warning labels and information signs on the machine
The warning labels and information signs on the machine must be followed
(see chapter "Labels" 3.3 Labels, page 20).
The warning labels and information signs must be kept legible and must be
replaced if necessary. For this purpose, contact your nearest HATZ service
station.
HATZ
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians (see chapter 2 General in-
formation, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.
Safety equipment
Safety equipment must not be modified and must not be rendered ineffective
during normal operation.
13Operator's Manual
Page 14
Safety 1B20, 1B27, 1B30, 1B40, 1B50
General safety instructions
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in the Operator's Manual.
▪ Heed the warnings on the machine and in the Operator's
Manual.
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪ The personnel must have read and understood this Opera-
tor's Manual or must possess the qualifications necessary
for working with this equipment, acquired in training/instructional courses.
▪ Only qualified personnel is permitted to operate and main-
tain this machine.
▪ Failure to comply will cause the warranty to be void.
WARNING
14
Danger of injury from failure to follow the operating instructions and from performing unauthorized tasks on the machine.
▪ Follow all instructions.
▪ Do not perform activities for which no qualification is avail-
able. Contact properly trained personnel if necessary.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist (see chapter 6.1 Transport,
page 29).
Operator's Manual
HATZ
Page 15
1B20, 1B27, 1B30, 1B40, 1B50 Safety
3.2.2 Machine-specific safety instructions for operation
Introduction
The machine can pose residual risks during operation. To eliminate these
risks, all persons working on the machine must follow the general and machine-specific safety instructions.
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine.
These assembly instructions contain important information on safe installation.
If the engine is installed in a machine or assembled with other machines to
form a machine, it is prohibited to start the engine before it has been determined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations.
Safe operation
▪ Before switching on the machine, ensure that no one can be injured when
the machine is started up.
▪ During machine operation, ensure that unauthorized persons do not have
access to the area in which the machine has an impact.
▪ Parts of the exhaust gas system and the surface of the engine become hot
during operation. Risk of injury from touching hot parts! Let the engine cool
before maintenance.
▪ Do not refuel during operation.
HATZ
Faults
▪ Immediately eliminate faults that compromise safety.
▪ Switch off the machine and do not take into service again until all faults
have been eliminated.
Safety instructions for operation
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
15Operator's Manual
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Safety 1B20, 1B27, 1B30, 1B40, 1B50
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
CAUTION
Danger of injury from faulty starter rope.
A chafed starter rope can rip and cause injuries.
▪ Before using the starter rope, check for abrasion; replace
the rope if necessary.
3.2.3 Machine-specific safety instructions for maintenance work
Introduction
The machine can pose residual risks during maintenance. To eliminate
these risks, all persons working on the machine must follow the general and
machine-specific safety instructions.
16
Maintenance intervals
▪ Strictly adhere to the maintenance intervals.
▪ Check the safety equipment regularly to ensure it is in good condition and
functioning properly.
▪ Check connections, cables and fasteners regularly to ensure they are in
good condition.
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians. We recommend that you
work with one of the over 500 HATZ service stations.
Replacing parts
▪ When replacing defective components, we recommend that you use gen-
uine HATZ original spare parts (see chapter 2 General information, page
6).
▪ When disposing of parts that can no longer be used, do so in accordance
with local environmental regulations or send them to a recycling center.
Operator's Manual
HATZ
Page 17
1B20, 1B27, 1B30, 1B40, 1B50 Safety
Measures following maintenance and troubleshooting
▪ Securely reconnect loose electrical connections; check that the electrical
components and equipment are functioning properly.
▪ Check the entire machine for foreign bodies; remove any foreign bodies.
Safety instructions for maintenance work
DANGER
Danger of explosion from flammable cleaning agents.
Cleaning with benzene is an explosion hazard. It is highly
flammable, can become electrostatically charged, and can generate an explosive gas/air mixture.
▪ Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
▪ Comply with manufacturer's instructions.
WARNING
Danger of injury from compressed air and dust particles.
Eye injuries may occur when cleaning with compressed air.
▪ Wear safety goggles.
HATZ
CAUTION
Danger of injury if maintenance instructions are not followed.
▪ Only perform maintenance when the engine is switched off.
▪ Protect start-up devices (crank handle, recoil start or start-
ing key) from unauthorized access.
▪ For engines with a starter: Disconnect the negative battery
terminal.
▪ When the maintenance work has been completed, ensure
that all tools are removed from the machine.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
17Operator's Manual
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Safety 1B20, 1B27, 1B30, 1B40, 1B50
3.2.4 Electrical equipment
Safety notes
DANGER
Danger to life, danger of injury or danger of property damage due to incorrect use of batteries.
▪ Do not place tools on the battery.
▪ Before performing work on the electrical equipment, always
disconnect the negative battery terminal.
▪ Never swap the positive (+) and negative (–) battery termi-
nals.
▪ When installing the battery, first connect the positive cable
and then the negative cable.
▪ When removing the battery, first disconnect the negative
cable and then the positive cable.
▪ It is imperative that you prevent short circuits and mass con-
tact of current-carrying cables.
▪ If faults occur, check the cable connections for good con-
tact.
DANGER
18
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪ Keep batteries away from open flames and incendiary
sparks.
▪ Do not smoke when working with batteries.
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
▪ Protect your eyes, skin, and clothing from corrosive battery
acid.
▪ Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.
Operator's Manual
HATZ
Page 19
1B20, 1B27, 1B30, 1B40, 1B50 Safety
NOTICE
▪ The necessary wiring diagrams are included with the ma-
chine if it is equipped with electrical equipment. Additional
wiring diagrams can be requested when needed.
▪ We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
▪ Promptly replace faulty indicator lamps.
▪ Do not pull out the starting key during operation.
▪ Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪ When performing a manual emergency start, leave the (possibly depleted)
battery connected.
▪ When cleaning, do no spray the electrical equipment components with a
water jet or high pressure cleaner.
▪ When performing welding work on the machine, disconnect the battery
and place the ground clamp of the welding equipment as close as possible
to the welding area. Disconnect the plug-in connection to the voltage regulator.
▪ The following additionally applies before starting emergency operation
without the battery:
– In models with an instrument box on the engine, disconnect the
plug-in connection to the voltage regulator. Turn the starting key to
pos. "0" and remove.
– In models with an external instrument box, disconnect the plug-in
connection to the instrument box.
HATZ
19Operator's Manual
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Safety 1B20, 1B27, 1B30, 1B40, 1B50
1B20: 0,20mm 1B27: 0,10mm
1B30: 0,10mm 1B40: 0,10mm
1B50: 0,10mm
0000 051 104 06
IN
EX
= 1h
500h
250h
max
max
OIL
0000 051 300 02
321
0000 053 338 01
3.3 Labels
Warning labels and information signs on the engine
Label Meaning
Maintenance instructions (see chapter 8.1 General maintenance instruc-
tions, page 55)
Start the engine with the recoil start
(see chapter 7.4.1 Starting the en-
gine with recoil start (up to -6 °C),
page 38)
20
CAUTION
Danger of injury from faulty starter
rope.
A chafed starter rope can snap and
cause injuries.
▪ Before using the starter rope,
check for abrasion; replace the
rope if necessary.
Operator's Manual
HATZ
Page 21
1B20, 1B27, 1B30, 1B40, 1B50 Safety
BIO
DIESEL
052 356 02
DIESEL
052 356 01
BIO
Label Meaning
Speed adjustment with connecting
rod (additional equipment)
Refuel with diesel fuel only. For the
specification, see chapter 4.5 Fuel,
page 26
Do not use bio diesel.
Changing the fuel filter
(see chapter 8.2.11 Changing the
fuel filter, page 78)
HATZ
21Operator's Manual
Page 22
Technical data 1B20, 1B27, 1B30, 1B40, 1B50
4 Technical data
4.1 Engine information and filling quantities
Type 1B20 1B27 1B30 1B40 1B50
Type Air cooled four stroke diesel engine
Combustion system Direct injection
Number of cylinders 1 1 1 1 1
Bore/stroke mm 69 / 65 74 / 65 80 / 69 88 / 76 93 / 76
Displacement cm
Tank capacity Ltr. 3 3 5 5 5
Engine oil capacity
Without oil sump
With oil sump
Difference between the
"max." and "min."
marks
Without oil sump
With oil sump
Engine oil consumption (after running-in period)
Engine oil pressure at oil
temperature of 100°C
Sense of rotation on power
take-off side
Tappet clearance
at 10–30°C
inlet/outlet mm 0.20 0.10 0.10 0.10 0.10
Max. perm. inclination during continuous operation in
direction
Weight (incl. fuel tank, air
filter, silencer, recoil start
and electric start)
Battery capacity Min/max 12V – 36/55Ah/24V – 24/44Ah
1)
These values are approximations only. The max. mark on the dipstick is
decisive in any case (see chapter 7.6 Checking the oil level and adding oil if
necessary, page 47).
2)
Exceeding these values will cause engine damage.
3
Approx. ltr.
Approx. ltr.
Approx. ltr.
Approx. ltr.
243 280 347 462 517
0.9
2.6
0.5
1.6
1)
1)
1)
1)
0.9
0.5
1)
-
1)
-
1.1
2.8
0.5
1.8
1)
1)
1)
1)
1.5
3.2
0.8
2.2
1)
1.5
1)
1)
0.8
1)
-
-
Max. 1% of fuel consumption, pertaining to full load
Approx. 2.5bar at 3000rpm
Left
Flywheel low 25°
Other directions 35°
2)
2)
Approx. kg 33 34 40 55 56
1)
1)
22
Operator's Manual
HATZ
Page 23
1B20, 1B27, 1B30, 1B40, 1B50 Technical data
➀
➁
➂
➃
Screw tightening torque
Designation Nm
Oil drain screw 50
4.2 Engine type plate
The engine type plate is located on the sound protection hood and contains
the following engine information:
HATZ
1 Number of the engine family or the EU approval (for engines with ex-
haust certificate only)
2 Engine type, customer specification and setting of pumping start (°
crankshaft before top dead center)
3 Engine serial number
4 Max. engine speed (rpm)
5 Model year
6 Displacement (liters) and inspection requirement for special settings
7 Injection pump effective stroke (mm) and engine capacity (kW)
8 "Constant speed only” (for engines with EPA/CARB exhaust certificate
only)
9 "Variable speed” (for engines with EPA/CARB exhaust certificate only)
23Operator's Manual
Page 24
Technical data 1B20, 1B27, 1B30, 1B40, 1B50
i
The following data must always be specified for requests and spare part orders
2 Engine type and customer specification
3 Engine serial number
4 Max. engine speed (rpm)
4.3 Physical operating conditions
Engine adjustment
The engine is normally adjusted to operate within the standard reference
conditions stipulated in ISO3046-1:
Parameter Unit Value
Intake air temperature °C +25
K 298
Relative humidity % 30
Air pressure
(at approx. 100 meters above sea
level)
NOTICE
If the machine is operated at high altitudes and high temperatures, adjustment of the engine setting may be necessary if the
climatic conditions were not taken into account when the machine was ordered. If this is the case, please contact your nearest HATZ service station.
kPa 100
24
Operator's Manual
HATZ
Page 25
1B20, 1B27, 1B30, 1B40, 1B50 Technical data
-40
-30
-20
-10
0
10
20
30
40
50
104
86
68
50
32
14
-4
-22
-40
OIL : SAE .. .
°C°F
5W/ 30
5W/ 40
10
W/
4
0
10W/ 3
0
15W
/
40
30
40
122
10
W
4.4 Engine oil
Oil quality
All brand name oils that satisfy at least the following specification are suitable:
▪ ACEA – B3 / E4 or better
▪ API – CF / CH-4 or better
If engine oils of a low quality standard are used, the oil change interval must
be reduced to 150 operating hours.
Oil viscosity
HATZ
Choose the recommended viscosity based on the type of start (recoil,
crankhandle or electric) and on the engine temperature at which the engine
will be operated.
CAUTION
Engine damage from unsuitable engine oil.
Unsuitable engine oil considerably reduces engine service life.
Only use engine oil that fulfills the specifications stipulated
above.
25Operator's Manual
Page 26
Technical data 1B20, 1B27, 1B30, 1B40, 1B50
4.5 Fuel
Fuel type
All types of diesel fuel that meet the minimum requirements of the following
specifications are suitable:
▪ EN 590 or
▪ BS 2869 A1 / A2 or
▪ ASTM D 975- 1D / 2D
CAUTION
Danger of engine damage from low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪ The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
Winter fuel
When outside temperatures drop below 0°C, use winter fuel or mix in petroleum in advance:
Lowest ambient temperature at start [°C]
0 to -10
-10 to -15
-15 to -20
-20 to -30
Percentage of petroleum [%]for
Summer fuel Winter fuel
20
30
50
‑
‑
‑
20
50
26
Operator's Manual
HATZ
Page 27
1B20, 1B27, 1B30, 1B40, 1B50 Engine design
2
8 9 10
9
11
12
13
14
15
16
17
18
19
20
21
3
4
6
5
7
1 22
5 Engine design
Overview
1 Type plate
2 Cylinder head cover
3 Silencer with contact protection
4 Exhaust manifold with exhaust screen
5 Oil pressure switch
HATZ
6 Starter
7 Voltage regulator
8 Crankshaft – power take-off (pto)
9 Oil drain screw
10 Speed control lever
11 Screw cap for oil filter
12 Engine mount
13 Starting key
14 Indicators
15 Intake opening for cooling and combustion air
16 Oil filling opening and dipstick
1)
1)
1)
1)
1)
27Operator's Manual
Page 28
Engine design 1B20, 1B27, 1B30, 1B40, 1B50
17 Recoil start
18 Stop pin (option)
19 Dry air filter
20 Lifting eye
21 Fuel cap
22 Sound protection hood
1)
Only in model with electrical equipment.
The engine can optionally be supplied with an external instrument box.
28
Operator's Manual
HATZ
Page 29
1B20, 1B27, 1B30, 1B40, 1B50 Transport, assembly and commissioning
6 Transport, assembly and commissioning
6.1 Transport
Safety notes
WARNING
Danger of injury from improper lifting and transport.
Danger of crushing from falling or tipping of the engine.
▪ Only use the lifting eye already mounted on the machine for
lifting.
▪ Only use a suitable hoist with a sufficient carrying capacity.
▪ Do not remain under suspended loads.
CAUTION
Only use the lifting eye for transporting the engine.
Do not use for lifting the entire machine.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist.
HATZ
NOTICE
Danger of environmental damage from leaking fluid.
If the machine is tilted, engine oil and fuel can run out.
▪ Only transport the machine in an upright position.
Transport conditions
▪ When transporting the machine, follow the safety instructions.
▪ When transporting, follow the applicable safety and accident prevention
regulations of the trade associations.
▪ After delivery, check the machine for completeness and transport damage.
▪ Only transport the machine when it is switched off and has cooled down.
▪ If you have questions on transporting the machine, please contact your
nearest HATZ service station. For contact data, see chapter 1 Impres-
sum, page 5 or www.hatz-diesel.com.
29Operator's Manual
Page 30
Transport, assembly and commissioning 1B20, 1B27, 1B30, 1B40, 1B50
Access to the lifting eye
Step Activity Figure
1 Unscrew the air filter cover
(1).
2 Remove the sound protec-
tion hood (2).
3 Attach the hoist securely to
the lifting eye (3).
4 After completion of trans-
6.2 Installation notes
HATZ diesel engines are efficient, robust and have a long service life. Therefore, they are usually installed in machines that are used for commercial purposes.
The machine manufacturer must follow the applicable regulations regarding
machine safety – the engine is a part of a machine.
30
portation, refit the sound protection hood and cover for
the air filter.
Operator's Manual
HATZ
Page 31
1B20, 1B27, 1B30, 1B40, 1B50 Transport, assembly and commissioning
Depending on the use and installation of the engine, it may be necessary for
the machine manufacturer and machine user to install safety equipment to
prevent inappropriate use. Note the following:
▪ Parts of the exhaust gas system and the engine surface become hot dur-
ing operation and may not be touched until they cool down after the engine is switched off.
▪ Incorrect cable connections and incorrect operation of the electrical equip-
ment can lead to sparking and must be avoided.
▪ After the engine is installed in the machine, rotating parts must be pro-
tected against contact.
HATZ safety equipment is available for the belt drive of the cooling fan and
alternator.
▪ Comply with all notices and warning labels on the engine and keep them
in a legible condition. If a label should become detached or be difficult to
read, it must be replaced promptly. For this purpose, contact your nearest
HATZ service station.
▪ Any improper modification of the engine results in a loss of liability cover-
age for resulting damage.
Only regular maintenance, as specified in this Operators Manual, will maintain the operating readiness of the engine.
The assembly instructions contain important information on how to safely
assemble the engine. They are available from any Hatz service station.
If you have any questions, please contact your nearest HATZ service sta-
tion before commissioning the engine.
6.3 Preparations for commissioning
▪ Check the delivered parts for completeness, damage, and other noticeable
issues.
▪ Ensure that the setup location is adequately ventilated.
HATZ
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
31Operator's Manual
Page 32
Transport, assembly and commissioning 1B20, 1B27, 1B30, 1B40, 1B50
6.4 Filling engine oil (first filling)
Engines are normally delivered without an engine oil filling.
Safety notes
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
CAUTION
Danger of later engine damage.
▪ Operating the engine with an oil level below the min. mark
or above the max. mark can lead to engine damage.
▪ When checking the oil level, the engine must be horizontal
and have been switched off for a few minutes.
Overview
32
1 Dipstick
2 Oil refilling container
Procedure
Step Activity
1 Unscrew the dipstick (1) and clean it.
2 Fill engine oil. For the specification and viscosity, see chapter
4.4 Engine oil, page 25. See chapter 4.1 Engine information and
filling quantities, page 22 for the engine oil capacity.
Operator's Manual
HATZ
Page 33
1B20, 1B27, 1B30, 1B40, 1B50 Transport, assembly and commissioning
Step Activity
3 Reinsert the dipstick and screw it tight.
4 Unscrew the dipstick and check the oil level.
5 If required, top up engine oil to the max. mark.
6 Reinsert the dipstick and screw it tight.
6.5 Filling the oil bath air filter (option)
Overview
1 Clamp fastener (2x opposing)
2 Oil container
3 Filter insert
4 Gasket
5 Level mark
HATZ
Procedure
Step Activity
1 Release the clamp fasteners (1).
2 Remove the oil container (2).
3 Take the filter insert (3) out of the oil container.
4 Fill the oil container with engine oil up to the level mark (5).
2 Insert the long end of the filter insert (3) into the oil container.
3 Mount the oil container, ensuring that the gasket (4) is properly
positioned and the locks (1) are correctly fastened.
33Operator's Manual
Page 34
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
7 Operation and use
7.1 Safety notes
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in chapter 3 Safety, page 7.
WARNING
Danger of injury from damage and defects on the machine.
▪ Do not take the machine into service if damage has been lo-
calized and identified.
▪ Replace faulty components.
WARNING
Danger of injury from failure to follow the operating instructions and from performing unauthorized tasks on the machine.
▪ Define the responsibilities of the personnel taking the ma-
chine into service.
▪ Replace faulty machine parts immediately.
▪ Check the installation conditions when the machine is first
taken into service and after the machine has been inactive
for a lengthy period.
34
CAUTION
Danger of engine damage from low load operation.
Operating the engine at no load or at very low load for an extended period can impair the running characteristics of the engine.
▪ Make sure that the engine load is at least 15%.
▪ Before switching off the engine following low load operation,
briefly operate it at a considerably higher load.
CAUTION
Exceeding of the permissible forces at the speed control
lever and stop pin can cause damage to the stops and inside regulator parts.
Please note the following figure.
Operator's Manual
HATZ
Page 35
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
F<15 N
STOP
76.5°
STOP
F 30 N
M Nm
<
<
START
2.3
Max. permissible forces on the speed control lever and stop pin
7.2 Performing tests
Before starting
Before starting the engine, several tests need to be performed to ensure the
machine is working properly.
Procedure
Step Test
1 The machine is standing securely and on a level surface.
2 The installation location is adequately ventilated.
3 There is a sufficient amount of fuel in the fuel tank (see chapter
7.7 Refueling, page 50).
4 There is a sufficient amount of engine oil in the engine housing
(see chapter 7.6 Checking the oil level and adding oil if neces-
sary, page 47).
5 The starter rope of the recoil start does not exhibit abrasion
(hand start).
6 Fill the oil bath air filter (option) with engine oil (see chapter 7.6.2
Oil level in the oil bath filter (option), page 49).
7 No persons are located in the danger zone of the engine or ma-
chine.
8 All safety equipment is in place.
HATZ
35Operator's Manual
Page 36
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
i
7.3 Setting the speed control
Safety note
CAUTION
Damage to the diesel engine due to inadequate lubrication.
▪ After the engine has been out of use for an extended period
(approx. 6 months or longer) or when the engine is first
taken into service, operate the engine at a low set speed
and without a load for approx. 20 seconds after starting.
This ensures good lubrication of all bearing points before
the speed and load are increased.
Overview
36
1 Speed control lever
Procedure
Step Activity
1 First move the speed control lever (1) to the "Stop" position.
2 Depending on the situation, place the speed control lever in ei-
ther the "1/2" or "Start" position.
NOTICE
A lower speed setting will cause less exhaust smoke when starting.
Operator's Manual
HATZ
Page 37
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
7.4 Starting the engine
Starting options
A hand start mechanism is standard equipment for the engine. A starter can
be installed as an option.
If possible, separate the engine from the machine being driven by uncoupling it. Always switch the machine into idle mode.
Safety notes
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
WARNING
Danger of injury from faulty starter rope.
A chafed starter rope can rip and cause injuries.
▪ Before using the starter rope, check for abrasion; replace
the rope if necessary.
HATZ
CAUTION
Danger of injury and danger of engine damage from the use
of starting fluid.
▪ Danger of injury during hand starting because the use of
starting fluid can result in uncontrolled ignitions.
▪ Engine damage from uncontrolled ignition.
▪ Never use starting fluid.
37Operator's Manual
Page 38
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
7.4.1 Starting the engine with recoil start (up to -6 °C)
Overview
1 Grip
2 Recoil start cover
3 Diagram of starting procedure
Procedure
38
Step Activity
1 Check the speed adjustment (see chapter 7.3 Setting the speed
control, page 36).
2 Slowly pull out the grip with the rope until you encounter slight
resistance.
3 Let the rope run back in to be able to use the entire rope length
for the starting procedure.
4 Hold the grip with both hands.
5 Pull the starting rope evenly and with increasing speed (do not
tear at it jerkily) until the engine starts.
Operator's Manual
HATZ
Page 39
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
i
0
I
II
0
I
II
NOTICE
When the exhaust emits white smoke after several failed
start procedures:
▪ Move the speed controller lever to the "Stop" position.
▪ Pull the starting rope all the way out five times.
▪ Reset the speed adjustment (see chapter 7.3 Setting the
speed control, page 36).
▪ Repeat the start procedure.
7.4.2 Starting the engine with a starter
Overview — HATZ instrument boxes
Standard
HATZ
Option
39Operator's Manual
Page 40
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
1 Protective cap
2 Starting key
3 Pre glow display (option)
4 Air filter maintenance indicator (not activated)
5 Engine temperature display (option)
6 Oil pressure display
7 Charge control
8 Operating display
9 Operating hours counter (option)
Ignition lock
0 Off
I Operation
II Start
Indicator lamps
When the starting key is turned to position "I" various indicator lamps flash or
light up (depending on the equipment version). If there is a fault, the applicable indicator does not go out after the engine start or it lights up again during
operation.
40
Explanation of symbols
Symbol Meaning
Operating display
Lights up during operation when there is no engine fault.
Charge control
Fault in the alternator or alternator charging circuit. The battery
is no longer charged. Eliminate the fault immediately.
Oil pressure display
Switch off the engine immediately! Danger of engine damage.
Check the oil level (see chapter 7.6 Checking the oil level and
adding oil if necessary, page 47).
Contact Hatz service if the oil level is correct.
Engine temperature display
Switch off the engine immediately! Danger of engine damage.
Engine temperature is impermissibly high. For details of troubleshooting, see chapter 9.1 Troubleshooting, page 86.
Pre glow display
Lights at temperatures below 0°C. Start the engine when the
display has gone out.
Operator's Manual
HATZ
Page 41
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
i
Overview – Fuel shut-off valve (option)
1 Fuel shut-off valve
Description of functions
When the starting key is moved to position I the fuel shut-off valve (1) is
electrically unlocked. The fuel supply to the injection pump is enabled, the
engine is ready to start. When the engine is running, turning the starting key
to position 0 locks the fuel shut-off valve and thereby blocks the fuel supply
to the injection pump, the engine switches off.
This fuel shut-off valve is also used in association with the electrical automatic shutoff. When faults occur the automatic shutoff switches off the engine. For troubleshooting details, see chapter 9.1 Troubleshooting, page
86.
In special situations an emergency start can also be attempted (see chapter 9.2 Emergency start, page 91).
HATZ
Procedure – Starting the engine with a starter
NOTICE
▪ Start for max. 30 seconds. If the engine is still not running
after that, turn the starting key back to position "0" and eliminate the cause (see chapter 9.1 Troubleshooting, page
86).
▪ Turn the starting key to position "0" every time you want to
start the engine.
▪ The anti repeat device in the ignition lock makes it impossi-
ble for the starter to engage while the engine is running and
become damaged.
Step Activity
1 Check the speed adjustment (see chapter 7.3 Setting the speed
control, page 36).
2 Remove the protective cap (1) from the ignition lock.
41Operator's Manual
Page 42
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
i
i
Step Activity
3 Insert the starting key all the way and turn to position "I".
When the pre glow display (3) lights up, wait until it goes out
then continue with step 3.
4 Turn the starting key to position "II".
5 As soon as the engine is running, release the starting key.
▪ The starting key springs back to position "I" and remains in
this position during operation.
▪ The charge control (7) and oil pressure display (6) go out.
▪ Operating display (8) lights up and signals there is no engine
fault.
NOTICE
▪ In case of irregularities, switch off the engine immediately.
▪ Identify the fault and eliminate it.
▪ For details of troubleshooting, see chapter 9.1 Trou-
bleshooting, page 86.
Automatic electrical shutoff (option)
The identifying feature of the electrical automatic shutoff is brief flashing of
all indicator lamps after the starting key is turned to position "I".
42
NOTICE
▪ If the engine stops again immediately after starting, or stops
independently during operation, this is an indication that a
monitoring element of the automatic shutoff has been activated.
▪ Remedy the fault before making further starting attempts
(see chapter 9.1 Troubleshooting, page 86).
▪ Despite the automatic switch-off, check the oil level every
8–15 operating hours (see chapter 7.6 Checking the oil level
and adding oil if necessary, page 47).
Procedure when faults occur
Step Activity
1 Check the indicators (5-7).
After the engine comes to a standstill, the fault will continue to
be displayed by the indicator for approx. another 2 minutes.
2 Then the electrical equipment switches off automatically.
3 Set the starting key to position "0".
Operator's Manual
HATZ
Page 43
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
i
Step Activity
4 Turn the starting key back to position "I".
The fault display lights up again.
Remedy the fault before making further starting attempts (see
chapter 9.1 Troubleshooting, page 86).
The indicator then goes out at the next start.
7.5 Switching off the engine
CAUTION
Danger of injury from unauthorized access.
There is a danger of injury if unauthorized persons handle the
machine.
▪ Protect the starting key against unauthorized access during
breaks in operation or after completing work.
CAUTION
Protect the ignition lock against dirt and moisture.
▪ With the starting key pulled out, seal the ignition lock with
the protective cap.
Methods of switching off the engine
The engine can be switched off in different ways depending on how it is
equipped:
▪ Speed control lever (mechanical)
▪ Stop pin (mechanical)
▪ Starting key (electrical)
7.5.1 Switching off the engine (mechanical)
NOTICE
Engines with a blocked lower idle speed cannot be switched off
with the speed control lever. In this case, the engine is switched
off with the stop pin or starting key, depending on how the engine is equipped.
HATZ
43Operator's Manual
Page 44
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
Overview
44
1 Speed control lever
2 Stop pin (additional equipment)
3 Connecting rod (additional equipment)
Procedure
Step Activity
Speed control lever
1 Push the speed control lever (1) all the way to the "STOP" po-
sition. The engine switches off.
Stop pin
1 Press and hold the stop pin (2) until the engine switches off.
2 Release the stop pin and ensure that it returns to its original
position.
Speed adjustment with connecting rod (additional equipment)
1 Move the speed adjustment with the connecting rod (3) to the
"STOP" position and press it until the engine switches off.
Operator's Manual
HATZ
Page 45
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
0
I
0
I
7.5.2 Switching off the engine (electrical)
Overview — HATZ instrument boxes
Standard
Option
HATZ
45Operator's Manual
Page 46
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
i
Fuel shut-off valve
1 Protective cap
2 Starting key
3 Fuel shut-off valve
Ignition lock
0 Off
I Operation
Procedure
46
Step Activity
1 Turn the starting key (2) to position "0".
▪ The fuel shut-off valve shuts off the fuel supply to the injection
pump. The engine switches off.
▪ All indicator lamps go out.
2 Remove the starting key.
3 Seal the ignition lock with the protective cap (1).
NOTICE
Danger of exhaustive battery discharge.
▪ When the machine is switched off, always turn the starting
key to position "0" or else the battery may become fully discharged.
Operator's Manual
HATZ
Page 47
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
7.6 Checking the oil level and adding oil if necessary
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Wear safety gloves.
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
CAUTION
Danger of later engine damage.
▪ Operating the engine with an oil level below the min. mark
or above the max. mark can lead to engine damage.
▪ When checking the oil level, the engine must be horizontal
and have been switched off for a few minutes.
HATZ
47Operator's Manual
Page 48
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
7.6.1 Engine oil level
Overview
1 Dipstick
2 Oil refilling container
Procedure
Step Activity
1 Switch off the engine and wait several minutes for the engine oil
to collect in the crankcase. Engine must be level.
2 Remove contamination on the engine in the area of the dipstick.
3 Unscrew the dipstick and clean it.
4 Reinsert the dipstick and screw it tight.
5 Unscrew the dipstick and check the oil level.
6 If the oil level is close to the min. mark, add engine oil to the
max. mark.
7 Reinsert the dipstick and screw it tight.
48
Operator's Manual
HATZ
Page 49
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
7.6.2 Oil level in the oil bath filter (option)
Overview
1 Clamp fastener (2x opposing)
2 Oil container
3 Filter insert
4 Gasket
5 Level mark
Procedure
HATZ
Step Activity
1 Release the clamp fasteners (1).
2 Remove the oil container (2).
3 Take the filter insert (3) out of the oil container.
4 Check for dirt.
When the deposited dirt has reached approximately half the
height of the oil filling or the oil has become viscous, clean the
oil bath air filter (see chapter 8.2.7 Maintaining the oil bath filter,
page 68).
4 Otherwise check the oil level and fill with engine oil up to the
level mark (5) as required.
5 Mount the oil container, ensuring that the gasket (4) is properly
positioned and the clamp fasteners (1) are correctly fastened.
49Operator's Manual
Page 50
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
7.7 Refueling
Safety notes
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
CAUTION
Danger of environmental damage from spilled fuel.
Do not overfill the fuel tank and do not spill fuel.
▪ Collect any leaking fuel and dispose of it according to local
environmental regulations.
CAUTION
Engine damage from using low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪ Only use the fuel specified in chapter 4.5 Fuel, page 26.
▪ The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
50
Operator's Manual
HATZ
Page 51
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
Overview
1 Fuel cap
2 Fuel tank
Procedure
Step Activity Figure
1 Open the fuel cap.
HATZ
2 Fill the fuel tank with diesel
fuel.
51Operator's Manual
Page 52
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
i
i
Step Activity Figure
3 Close the fuel cap.
NOTICE
▪ Before starting for the first time or if the fuel system is
empty, fill the fuel tank fully with diesel fuel. This causes the
fuel system to be bled automatically.
▪ Automatic bleeding is completed after a waiting period of
1-2 minutes. The engine is ready to start.
7.8 Checking the water separator
Safety notes
CAUTION
52
Danger of environmental damage from spilled fuel.
When water is drained from the water separator, a small amount
of fuel is drained as well.
▪ Collect any escaped water/fuel mixture and dispose of it ac-
cording to local environmental regulations.
NOTICE
The interval for checking the water separator depends entirely
on the proportion of water in the fuel and on the care exercised
during refueling; the water separator should be checked at least
once a week.
Operator's Manual
HATZ
Page 53
1B20, 1B27, 1B30, 1B40, 1B50 Operation and use
Overview
Water in the fuel tank collects at the lowest point of the fuel tank in the water
separator.
Standard Model with window
1 Drain screw, hex (standard)
2 Window (additional equipment)
3 Drain screw (manually operated)
Procedure
Step Activity
1 Model with window:
Check the window (2) for water content.
Collected water can be clearly identified by the noticeable separating line between the water and the diesel fuel above it.
2 Place a suitable container under the drain screw (1) or (3).
NOTE: In inaccessible locations, an extension hose can be
mounted on the drain screw (3).
3 Open the drain screw (1) or (3) and drain the water into the con-
tainer.
4 When fuel emerges, close the drain screw.
5 Dispose of the water-fuel mixture in an environmentally compati-
ble manner.
HATZ
53Operator's Manual
Page 54
Operation and use 1B20, 1B27, 1B30, 1B40, 1B50
7.9 Check the air filter warning indicator (option)
Overview
1 Rubber bellow
2 Green field
Procedure
Step Activity
1 Bring the engine briefly to maximum speed.
2 When the rubber bellow (1) contracts and covers over the green
field (2), immediately check the air filter system (see chapter
8.2.12 Maintaining the dry air filter, page 83).
3 Check the rubber bellow (1) several times daily under dusty con-
ditions.
54
Operator's Manual
HATZ
Page 55
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
8 Maintenance
8.1 General maintenance instructions
Safety notes
WARNING
Danger of injury from failure to follow the operating instructions and from performing unauthorized tasks on the machine.
▪ Follow all instructions.
▪ Do not perform activities for which no qualification is avail-
able. Contact properly trained personnel if necessary.
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in chapter 3 Safety, page 7.
▪ Maintenance tasks may only be performed by trained personnel.
▪ Accident prevention measures must be in accordance with the local acci-
dent prevention regulations.
▪ Perform setting and maintenance work at the specified intervals.
▪ Replace faulty machine parts as soon as possible.
▪ Always use personal protective equipment.
▪ Only use fully functional tools.
▪ Problems may occur if unsuitable spare parts have been installed. We
cannot accept responsibility for damage and secondary damage that result
from this. We therefore recommend the use of genuine Hatz original
spare parts.
▪ Closely adhere to the maintenance conditions prescribed in this Operators
Manual.
▪ Only make changes on the machine in agreement with the manufacturer.
▪ Only perform maintenance when the engine is switched off.
▪ Protect start-up devices (crank handle, recoil start or starting key) from
unauthorized access.
▪ After completing maintenance work, check that all tools, bolts, aids, and
other objects are removed from the machine and that all safety equipment
has been replaced.
▪ Before starting, ensure that no persons are located in the danger zone of
the engine or machine.
HATZ
55Operator's Manual
Page 56
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
i
▪ Adhere to legal regulations when handling and disposing of used oil, fil-
ters, and cleaning agents.
▪ For engines with an electric starter: Disconnect the negative battery termi-
nal before carrying out maintenance work.
Performance of maintenance work
The entire machine is designed to be maintenance friendly. Parts that require maintenance are easily accessible.
▪ Perform maintenance work faithfully at the specified intervals to prevent
premature wear of the machine.
▪ Follow the notice and warning labels on the machine.
▪ Always retighten screw connections loosened during maintenance work.
▪ After the necessary maintenance and repair work is completed, perform a
function test (test run).
▪ For maintenance work that is not listed and described in the maintenance
documentation, please contact your nearest HATZ service station.
8.2 Maintenance work
Safety note
CAUTION
Danger of injury if maintenance instructions are not followed.
▪ Only perform maintenance when the engine is switched off.
▪ Protect start-up devices (crank handle, recoil start or start-
ing key) from unauthorized access.
▪ For engines with a starter: Disconnect the negative battery
terminal.
▪ When the maintenance work has been completed, ensure
that all tools are removed from the machine.
8.2.1 Maintenance notice label
NOTICE
The illustrated maintenance label is delivered with every engine.
▪ It should be mounted on the engine or machine in a clearly
▪ The maintenance intervals specified on the maintenance
56
visible location.
plan must be adhered to (see chapter 8.2.2 Maintenance
plan, page 57)
Operator's Manual
HATZ
Page 57
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
1B20: 0,20mm 1B27: 0,10mm
1B30: 0,10mm 1B40: 0,10mm
1B50: 0,10mm
0000 051 104 06
= 1h
max
OIL
500h
250h
IN
EX
max
8.2.2 Maintenance plan
In new and generally overhauled engines, after 25 operating hours:
▪ Change the engine oil
▪ Check the tappet clearance and adjust if necessary
▪ Checking the screw connections (do not retighten the screws for attaching
the cylinder head)
In case of a low number of operating hours, change the engine oil no later
than every 12 months, regardless of the actual number of operating hours.
HATZ
The interval at which maintenance work should be performed on the fuel filter depends on the cleanliness of the fuel in use and may need to be shortened to 250 operating hours.
57Operator's Manual
Page 58
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
250h
Symbol Maintenance in-
terval
Every 8–15 operating hours or every day before
starting
Weekly Check the water separator. 7.8 Checking the
Every 250 operating hours
Maintenance activity/check Chapter
Check the oil level. 7.6 Checking the
oil level and
adding oil if nec-
essary, page 47
Check the engine oil level in
the bottom section of the oil
bath filter and examine the oil
for contamination. Change the
oil if it is sludgy.
In models with a cyclone precleaner: remove the dust trap.
Check the intake area of the
combustion and cooling air.
Check the air filter maintenance indicator.
Maintain the oil bath filter. 8.2.7 Maintaining
Change the engine oil. 8.2.4 Change the
Check and set the tappet
clearance.
Clean the cooling air area. 8.2.8 Clean the
Check the screw connections. 8.2.9 Check the
Clean the exhaust screen. 8.2.10 Clean the
7.6.2 Oil level in
the oil bath filter
(option), page 49
8.2.12 Maintaining the dry air filter, page 83
8.2.3 Checking
the intake area,
page 59
7.9 Check the air
filter warning indi-
cator (option),
page 54
water separator,
page 52
the oil bath filter,
page 68
engine oil, page
60
8.2.6 Check and
set the tappet
clearance, page
65
cooling air area,
page 70
screw connec-
tions, page 73
exhaust screen,
page 73
58
Operator's Manual
HATZ
Page 59
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
500h
i
Symbol Maintenance in-
terval
Every 500 operating hours
Every 1000 operating hours
8.2.3 Checking the intake area
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
NOTICE
In case of heavy contamination, shorten the maintenance intervals accordingly (see chapter 8.2.2 Maintenance plan, page 57).
Maintenance activity/check Chapter
Change the fuel filter. 8.2.11 Changing
the fuel filter,
page 78
Maintain the dry air filter. 8.2.12 Maintain-
ing the dry air fil-
ter, page 83
Clean the oil filter. 8.2.5 Clean the
oil filter, page 62
HATZ
Overview
Standard Model with cyclone
precleaner
1 Air intake opening
Model with oil bath filter
59Operator's Manual
Page 60
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
2 Intake area of cyclone precleaner
3 Dust outlet opening
4 Intake area of oil bath filter
Procedure
Step Activity
1 Check the air intake opening (1) for coarse contamination such
as leaves, heavy dust deposits, etc., and clean if necessary.
2 In models with a cyclone precleaner, also check and if neces-
sary clean the intake area (2) in addition to step 1.
Check that the dust outlet opening (3) is clear and clean it if
necessary.
3 In models with an oil bath filter, also check and if necessary
clean the intake area (4) in addition to step 1.
8.2.4 Change the engine oil
Safety notes
CAUTION
Danger of burns.
When working on the engine there is a danger of burns from hot
oil.
▪ Wear personal protective equipment (gloves).
60
CAUTION
Danger of environmental damage from spilled used oil.
Used oil is water-polluting.
▪ Do no allow it to enter the ground water, water bodies, or
sewage system.
▪ Collect the used oil and dispose of it according to local envi-
ronmental regulations.
Operator's Manual
HATZ
Page 61
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
CAUTION
Danger of later engine damage.
▪ Operating the engine with an oil level below the min. mark
or above the max. mark can lead to engine damage.
▪ When checking the oil level, the engine must be horizontal
and have been switched off for a few minutes.
NOTICE
▪ The engine must be level.
▪ The engine must be switched off.
▪ Only drain engine oil while it is warm.
HATZ
Overview
Without oil sump With oil sump
1 Oil drain screw
2 Gasket
61Operator's Manual
Page 62
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Procedure
Step Activity
1 Keep a container ready for collecting the used oil. The con-
tainer must be large enough to hold the entire amount of engine oil.
2 Unscrew the oil drain screw (1) and drain the oil entirely.
3 Clean the oil filter when required (every 1000 hours of opera-
tion), see chapter 8.2.5 Clean the oil filter, page 62.
4 Screw in the cleaned oil drain screw (1) with the new gasket
(2) and tighten.
Tightening torque: 50Nm.
5 Add engine oil (see chapter 4.4 Engine oil, page 25).
8.2.5 Clean the oil filter
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
62
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
▪ Wear safety goggles.
▪ Never direct the compressed air jet toward people or toward
yourself.
Operator's Manual
HATZ
Page 63
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
i
NOTICE
▪ Capture emerging oil in a suitable container.
▪ Dispose of the oil according to legal regulations.
NOTICE
▪ The oil filter should be cleaned when the engine oil is
changed (see chapter 8.2.4 Change the engine oil, page
60), since oil will run out when the filter is pulled out.
Procedure
Step Activity Figure
1 Loosen the screw (1) by ap-
prox. five turns.
HATZ
2 Pull the oil filter (2) out of the
housing.
63Operator's Manual
Page 64
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Step Activity Figure
3 Blow out the oil filter with com-
pressed air from the inside to
the outside.
4 Check the gasket (3) for dam-
age and renew if necessary.
5 Lightly oil the gaskets (3+4)
before mounting.
6 Insert the oil filter and press it
all the way in.
7 Before tightening the screw,
ensure that the tension springs
(5) rest against the oil filter at
both ends.
Tighten the screw.
64
8 Check the oil level and add oil
to the max. mark if necessary
(see chapter 7.6 Checking the
oil level and adding oil if necessary, page 47).
Operator's Manual
HATZ
Page 65
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
8.2.6 Check and set the tappet clearance
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine. Only
perform the settings while the engine is cold (10-30°C).
▪ Let the engine cool.
CAUTION
Damage from inadequate engine cooling.
Only operate the engine when all covers are installed.
Preparations
The preparations are performed in different ways depending on how the engine is equipped:
▪ Preparations on engine model with dry air filter
▪ Preparations on engine model with oil bath filter
▪ Preparations on engine model with rammer operation (1B20 R)
HATZ
Preparation - Engine model with dry air filter
Step Activity Figure
1 Unscrew the air filter cover (1).
65Operator's Manual
Page 66
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Step Activity Figure
2 Remove the sound protection
hood (2).
Preparation - Engine model with oil bath filter
Step Activity Figure
1 Release the screw (1).
2 Take off the cover plate (2)
with the sound protection hood
(3).
66
Preparations - Engine model with rammer operation (1B20 R)
Step Activity Figure
1 Unscrew the air filter cap (1).
Operator's Manual
HATZ
Page 67
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
Step Activity Figure
2 Remove the screws and nuts.
Remove the sound protection
hood (2).
Procedure
NOTICE
The steps described here can only be performed after the appropriate preparations have been completed.
Step Activity Figure
1 Remove dirt in the area of the
cylinder head cover (1).
HATZ
2 Remove the screws (2).
(2 screws in 1B20, 1B27 and
1B30, 3 screws in 1B40 and
1B50).
3 Take off the cover (3) with the
gasket (4).
67Operator's Manual
Page 68
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Step Activity Figure
4 Turn the engine in the sense of
rotation until the rocker arm (1)
has fully opened the outlet
valve. Then check the tappet
clearance at the rocker arm (2)
with a feeler gauge (3). For the
setting, see the chapter 4.1
Engine information and filling
quantities, page 22.
5 Turn the engine in the sense of
rotation until the rocker arm (2)
has fully opened the intake
valve. Now check the tappet
clearance at the rocker arm
(1).
6 If the tappet clearance needs
to corrected:
Release the screw (4) and turn
the hex nut (5) so the feeler
gauge (3) can be pulled
through with a barely perceptible resistance after the screw
(4) is tightened again.
7 Mount the cylinder head cover
with the new gasket and
tighten evenly.
8 Fully assemble the engine.
9 Perform a test run. Check the
cylinder head cover for tightness.
8.2.7 Maintaining the oil bath filter
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
68
Operator's Manual
HATZ
Page 69
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
CAUTION
Danger of injury
Repeated contact with diesel fuel can cause chapped and
cracked skin.
▪ Wear safety gloves.
CAUTION
▪ Do not repair the oil bath filter (weld/solder, etc.) as this may
lead to destruction of the filter or damage to the engine.
▪ For model with cyclone precleaner:
Never add oil to the dust trap.
HATZ
Procedures
The procedure differs depending on how the engine is equipped:
▪ Procedure – Cleaning the cyclone precleaner
▪ Procedure – Cleaning the oil bath air filter
Procedure – Cleaning the cyclone precleaner
Step Activity Figure
1 Take off the dust collection
container (1), empty it and
clean it without using liquids.
2 Also clean the intake opening
(2) without liquids.
3 Fully assemble the cyclone
precleaner and tighten with the
wing nut.
69Operator's Manual
Page 70
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Procedure – Cleaning the oil bath air filter
Step Activity Figure
1 Remove the oil container (1).
2 Remove the dirty oil and
sludge and clean the container.
3 Rinse the filter insert (2) in
diesel fuel. Before assembling
the filter, drip or wipe dry.
4 Clean the filter housing (3) if it
is very dirty.
5 Fully assembly the filter and
prepare it for operation by filling it with oil (see chapter 7.6.2
Oil level in the oil bath filter
(option), page 49).
8.2.8 Clean the cooling air area
Safety notes
70
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
▪ Wear safety goggles.
▪ Never direct the compressed air jet toward people or toward
yourself.
Operator's Manual
HATZ
Page 71
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
Procedure
Step Activity Figure
Dry contamination
1 Remove the screws (1).
2 Take off the recoil start (2) and
clean it.
HATZ
3 Clean the fan blades with a
suitable brush.
4 Then blow it out with com-
pressed air.
71Operator's Manual
Page 72
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Step Activity Figure
5 Also clean the cooling ribs of
the cylinder head (3) and cylinder (4) and blow out with compressed air.
6 Check the air gap (5) for dirt
and clean with compressed air
if necessary.
Note:
In 1B20 and 1B27, the air gap
(5) is markedly smaller than
the gap shown in the figure
(size approx. 5 mm).
7 The element can be checked
and cleaned through the holes
in the contact guard.
72
8 Mount the recoil start (2)
again.
Moist or oily contamination
1 Contact the HATZ service sta-
tion.
Operator's Manual
HATZ
Page 73
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
8.2.9 Check the screw connections
NOTICE
▪ Do not retighten the screws for attaching the cylinder head.
▪ The adjustment screws on the speed governor and the in-
jection system are secured with locking varnish and are not
permitted to be tightened or adjusted.
▪ Only retighten loose screw connections. Screw connections
can be secured with thread locking adhesive or tightened to
a defined torque. Retightening tight screw connections can
cause damage.
Procedure
Step Activity Figure
1 Check the condition of all
screw connections and ensure
that they are tight (for exceptions, see note and picture on
the right).
2 Tighten any lose screw con-
nections.
8.2.10 Clean the exhaust screen
Safety notes
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
HATZ
CAUTION
73Operator's Manual
Page 74
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
CAUTION
Danger of injury
There is a danger of injury when performing cleaning work at the
exhaust screen.
▪ Wear safety gloves.
Procedures
The exhaust screen can be cleaned in different ways depending on how the
engine is equipped:
▪ Cleaning the exhaust screen in standard models
▪ Cleaning the exhaust screen in models for rammer operation (1B20 R)
Cleaning the exhaust screen in standard models
Step Activity Figure
1 Release the hex nut and take
off the exhaust manifold (1).
74
2 Remove the hex nut from the
bracket (2) and pull out the
screen insert (3).
Operator's Manual
HATZ
Page 75
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
2
Step Activity Figure
3 Remove the deposits in the
screen insert with a suitable
wire brush.
4 Check the screen insert for
cracks or breakage, and replace if necessary.
5 Mount the screen insert and
bracket again.
6 Tighten the hex nut (1) by ap-
prox. one turn.
HATZ
7 Insert the exhaust manifold
with the bracket (2) into the
hole and pull it back to the outside so that the bracket can no
longer become unhooked.
8 Tighten the hex nut.
75Operator's Manual
Page 76
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Clean the exhaust screen in models for rammer operation (1B20 R)
Step Activity Figure
1 Release the hex nut and take
off the exhaust manifold (1).
2 Remove the hex nut from the
bracket (2) and pull out the
screen insert (3).
76
3 Remove the deposits in the
screen insert with a suitable
wire brush.
4 Check the screen insert for
cracks or breakage, and replace if necessary.
Operator's Manual
HATZ
Page 77
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
Step Activity Figure
5 Pull the hose (4) off of the ex-
haust manifold.
6 Check that the pipe connection
(5) is clear. Remove deposits
using a screwdriver or similar
instrument.
7 Attach the hose again.
8 Mount the screen insert and
bracket again.
9 Tighten the hex nut (1) by ap-
prox. one turn.
HATZ
77Operator's Manual
Page 78
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
2
Step Activity Figure
10 Insert the exhaust manifold
with the bracket (2) into the
hole and pull it back to the outside so that the bracket can no
longer become unhooked.
11 Tighten the hex nut.
8.2.11 Changing the fuel filter
Safety notes
DANGER
Fire hazard from fuel
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Do not spill fuel.
▪ No open flames when working on the fuel system.
▪ Do not smoke.
CAUTION
Danger of injury
Repeated contact with diesel fuel can cause chapped and
cracked skin.
▪ Wear safety gloves.
CAUTION
Danger of environmental damage from spilled fuel.
When the filter is removed, a small amount of fuel is drained as
well.
▪ Collect any escaping fuel and dispose of it according to lo-
cal environmental regulations.
78
Operator's Manual
HATZ
Page 79
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
CAUTION
Dirt particles can damage the injection system.
▪ Maintain clean conditions to ensure dirt does not enter the
fuel line.
Procedures
The fuel filter can be changed in different ways depending on how the engine is equipped:
▪ Model with fuel filter in tank
▪ Model with double fuel filter system
▪ Model with external fuel filter
Model with fuel filter in tank
Step Activity Figure
1 Open the fuel cap (1) and pull
the fuel filter (2) out of the tank
by the cord.
HATZ
2 Pull the fuel feed line (3) off of
the fuel filter (4) and insert a
new filter.
3 Insert the fuel filter back into
the tank.
4 Close the fuel cap.
The fuel system is bled automatically.
79Operator's Manual
Page 80
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
i
Model with double fuel filter system
NOTICE
▪ The advantage of this system is that dirt particles that may
enter the fuel line during a filter change are captured by the
downstream outside filter and are therefore unable to endanger the injection system.
▪ This outside filter is NOT permitted to be changed. Only
change the fuel filter in the tank.
Step Activity Figure
1 Do not change the mainte-
nance-free outside filter (1).
2 Open the fuel cap (2) and pull
the fuel filter (3) out of the tank
by the cord.
80
3 Pull the fuel feed line (4) off of
the fuel filter (5) and insert a
new filter.
4 Insert the fuel filter back into
the tank.
Operator's Manual
HATZ
Page 81
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
Step Activity Figure
5 Close the fuel cap.
The fuel system is bled automatically.
Model with external fuel filter
NOTICE
In the model with an external fuel filter, there is no fuel filter in
the tank.
Step Activity Figure
1a Water separator without win-
dow:
Empty the fuel tank (1). Open
the screw (2) and let the fuel
drain into a clean container.
The fuel can be used again
later.
HATZ
1b Water separator with win-
dow:
Empty the fuel tank (1). Open
the screw (2) and let the fuel
drain into a clean container.
The fuel can be used again
later.
2 Unscrew the fuel filter (3) from
the holder.
81Operator's Manual
Page 82
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
Step Activity Figure
3 Place a suitable container un-
der the fuel filter to collect the
remaining fuel.
4 Pull the fuel line (4) off of the
fuel filter (5) on both sides and
insert a new filter.
Observe the flow-through direction (arrows).
5 Attach the fuel filter to the
holder.
82
6 Fill the fuel tank with diesel
fuel (see chapter 7.7 Refuel-
ing, page 50).
The fuel system is bled automatically.
7 Check the fuel filter and lines
for tightness after a brief trial
run.
Operator's Manual
HATZ
Page 83
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
i
8.2.12 Maintaining the dry air filter
NOTICE
▪ Immediately clean the filter cartridge if the maintenance dis-
play appears at maximum speed.
▪ Renew the filter cartridge after a use period of 500 operating
hours.
Installing and removing the filter cartridge
Step Activity Figure
1 Unscrew the air filter cover
(1).
2 Unscrew the knurled nut (2)
and remove the air filter cartridge (3).
HATZ
3 Clean the filter housing (4)
and cover for the air filter.
Ingress of dirt or other foreign bodies into the intake
opening (5) of the engine absolutely must be avoided.
4 In the model with an air filter
maintenance display (6),
check the condition and
cleanliness of the valve shim
(7).
83Operator's Manual
Page 84
Maintenance 1B20, 1B27, 1B30, 1B40, 1B50
i
Step Activity Figure
5 The air filter cartridge either
needs to be replaced, or
cleaned or checked depending on the degree of contamination (see chapter 8.2.13
Checking and cleaning the
air filter cartridge, page 84).
6 Thinly coat the gasket (8)
with grease or engine oil to
make assembly and disassembly of the air filter cartridge easier. Do not coat
the face side (9).
7 Assemble in reverse order.
8.2.13 Checking and cleaning the air filter cartridge
84
Safety notes
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
▪ Wear safety goggles.
▪ Never direct the compressed air jet toward people or toward
yourself.
NOTICE
▪ The pressure must not exceed 5 bar.
▪ Even minor damage in the areas of the sealing surface, filter
paper or filter cartridge makes it impossible to reuse the filter cartridge.
Operator's Manual
HATZ
Page 85
1B20, 1B27, 1B30, 1B40, 1B50 Maintenance
Checking and cleaning the air filter cartridge
Step Activity Figure
Dry contamination
1 Blow out the filter cartridge
(1) with dry compressed air
from the inside to the outside
until dust no longer emerges.
2 Check the sealing surface
(2) of the filter cartridge for
damage.
3 Check the filter cartridge for
cracks in the filter paper and
other damage by holding it
against the light at a slant or
letting light from a lamp
shine through it.
4 Replace the filter cartridge if
necessary (see note).
Moist or oily contamination
1 Renew the filter cartridge.
HATZ
85Operator's Manual
Page 86
Faults 1B20, 1B27, 1B30, 1B40, 1B50
9 Faults
9.1 Troubleshooting
General troubleshooting notes
If the cases listed below have been worked through but the fault continues to
persist, please contact your nearest Hatz service station.
The engine does not start or is difficult to start, but can be turned easily as
usual
Possible causes Remedy Chapter
Speed control lever in
stop or idle position.
Stop pin in STOP position.
No fuel at the injection
pump.
Injection nozzle is not
functional.
Insufficient compression:
▪ Wrong tappet clear-
ance.
▪ Cylinder and/or pis-
ton ring wear.
Set the speed control lever to
the START position.
Move the stop pin by pulling it
lightly into the operating position.
Refuel. 7.7 Refueling,
Systematically check the entire fuel supply. If
this does not yield results:
▪ Check the feed line to the
engine.
▪ Check the fuel filter. 8.2.11 Changing
Contact Hatz Service.
Check the tappet clearance
and adjust if necessary.
Contact Hatz Service.
7.3 Setting the
speed control,
page 36
7.5.1 Switching
off the engine
(mechanical),
page 44
page 50
the fuel filter,
page 78
8.2.6 Check and
set the tappet
clearance, page
65
86
Operator's Manual
HATZ
Page 87
1B20, 1B27, 1B30, 1B40, 1B50 Faults
If equipped with a fuel shut-off valve or electrical automatic shutoff (engine
does not start)
Possible causes Remedy Chapter
The fuel shut-off valve
Contact Hatz Service.
is not functional and/or
irregularities in the
electrical equipment.
For low temperatures (engine does not start)
Possible causes Remedy Chapter
Temperature below
start limit temperature.
Activate the pre glow system
(option).
7.4.2 Starting the
engine with a
starter, page 39
Pre glow system (op-
Contact Hatz Service.
tion) defective.
Fuel gelled due to insufficient cold resistance.
Check whether the fuel that
emerges from the fuel feed line
is clear and not cloudy. If the
fuel has gelled, either thaw the
engine or drain the entire fuel
4.5 Fuel, page 26
8.2.11 Changing
the fuel filter,
page 78
supply system. Fill with a tem-
perature-resistant fuel mixture.
Oil is too viscous and
causes a too low
starter speed.
Insufficiently charged
battery.
Change the engine oil.
Add engine oil with a suitable
viscosity class.
Check the battery and contact
the service center if necessary.
8.2.4 Change the
engine oil, page
60
3.2.4 Electrical
equipment, page
18
Machine is not uncoupled.
If possible, separate the engine
from the machine by uncou-
pling it.
HATZ
The engine fires but then fails to continue running
Possible causes Remedy Chapter
The speed control
lever is not sufficiently
Set the lever to the Start posi-
tion.
set to the Start direction.
Machine is not uncoupled.
If possible, separate the engine
from the machine by uncou-
pling it.
7.3 Setting the
speed control,
page 36
87Operator's Manual
Page 88
Faults 1B20, 1B27, 1B30, 1B40, 1B50
Possible causes Remedy Chapter
Fuel filter is clogged. Change the fuel filter. 8.2.11 Changing
the fuel filter,
page 78
Stop signal from monitoring elements that are associated with the automatic switch-off (optional):
▪ No oil pressure. Check the oil level. 7.6 Checking the
oil level and
adding oil if necessary, page 47
▪ Faulty AC alternator. Contact Hatz Service.
▪ Engine temperature
too high.
Check the cooling air guides
for contamination or other im-
pairments.
8.2.8 Clean the
cooling air area,
page 70
Fault signal from the overvoltage and polarity protection system in
the voltage regulator:
Battery and/or other
cable connections are
incorrectly connected.
Check the electrical equipment
and its components or contact
Hatz service.
3.2.4 Electrical
equipment, page
18
Loose cable connections.
88
The starter does not switch on and the engine does not turn.
Possible causes Remedy Chapter
Irregularities in the electrical equipment:
Battery and/or other
cable connections are
incorrectly connected.
Check the electrical equipment
and its components or contact
Hatz service.
Cable connections are
loose and/or oxidized.
Battery is faulty and/or
not loaded.
Faulty starter.
Faulty relay, monitoring elements, etc.
Engine switches off spontaneously during operation
Possible causes Remedy Chapter
The tank ran out of fuel
Fill with fuel. 7.7 Refueling,
during operation.
Operator's Manual
3.2.4 Electrical
equipment, page
18
page 50
HATZ
Page 89
1B20, 1B27, 1B30, 1B40, 1B50 Faults
Possible causes Remedy Chapter
Fuel filter is clogged. Change the fuel filter. 8.2.11 Changing
the fuel filter,
page 78
Tank vent is clogged. Ensure that the tank is suffi-
ciently vented.
Air in the fuel system. Check the fuel system for air
ingress.
Check the bleed valve.
Mechanical faults. Contact Hatz Service.
With automatic electrical switch-off mechanism (option)
Possible causes Remedy Chapter
Stop signal of monitoring elements for:
▪ Oil pressure too low. Check the oil level. 7.6 Checking the
oil level and
adding oil if necessary, page 47
▪ Engine temperature
too high.
Check the cooling air guides
for contamination or other im-
pairments.
8.2.8 Clean the
cooling air area,
page 70
▪ Faulty AC alternator. Contact Hatz Service.
Fault signal from the overvoltage and polarity protection system in
the voltage regulator:
▪ Battery and/or other
cable connections
are incorrectly con-
Check the electrical equipment
and its components or contact
Hatz service.
3.2.4 Electrical
equipment, page
18
nected.
▪ Loose contacts on
cable connections.
HATZ
The engine loses power and speed
Possible causes Remedy Chapter
The speed adjustment
Block the speed adjustment.
lever does not stay in
the desired position.
The fuel supply is impaired:
▪ The tank ran out of
Add fuel. 7.7 Refueling,
fuel during operation.
page 50
89Operator's Manual
Page 90
Faults 1B20, 1B27, 1B30, 1B40, 1B50
Possible causes Remedy Chapter
▪ Fuel filter is clogged. Change the fuel filter. 8.2.11 Changing
the fuel filter,
page 78
▪ Inadequate tank
venting.
▪ Air in the fuel sys-
tem.
Ensure that the tank is suffi-
ciently vented.
Check the fuel system for air
ingress.
Check the bleed valve.
The engine loses power and speed, and black smoke emerges from the exhaust
Possible causes Remedy Chapter
Dirty air filter unit. Check the degree of dirt con-
tamination of the air filter, and
clean or renew it if necessary.
Tappet clearance not
Adjust the tappet clearance. 8.2.6 Check and
OK.
8.2.12 Maintaining the dry air filter, page 83
set the tappet
clearance, page
65
Injection nozzle not
Contact Hatz Service.
OK.
90
Engine becomes very hot. Indicator lamp for engine temperature (option)
lights up
Possible causes Remedy Chapter
Too much engine oil in
the engine.
Drain the engine oil to the up-
per mark of the dipstick.
7.6 Checking the
oil level and
adding oil if necessary, page 47
Inadequate cooling:
▪ Contamination in the
entire area of the
cooling air guides.
▪ Incompletely closed
air guide parts.
Clean the cooling air area. 8.2.8 Clean the
cooling air area,
page 70
Check the air guide parts and
shafts for completeness and
good sealing properties.
Operator's Manual
HATZ
Page 91
1B20, 1B27, 1B30, 1B40, 1B50 Faults
i
Condensate emerges from the exhaust silencer
Possible causes Remedy Chapter
Operation under no
load or very low load
for an extended period.
Operate the machine at a load
of approx. 70% if possible until
the exhaust outlet is dry again.
9.2 Emergency start
If an electrical fault signal occurs, the optional automatic switch-off locks the
fuel shut-off valve (1) and thereby stops the fuel supply to the injection pump
– the engine switches off. Also, a fault in the electrical equipment can cause
the engine to switch off.
If this occurs at a critical location, such as at a railroad crossing or intersection, an emergency start can be activated.
Safety notes
CAUTION
Danger when switching off the engine from the emergency
operation mode.
During the emergency operation mode, the engine can only be
switched off with the starting key if the emergency start lever is
first returned to its home position in a clockwise direction.
HATZ
CAUTION
Danger of later engine damage.
The monitoring components (oil pressure, charge control and
engine temperature) are deactivated in emergency operation.
▪ The oil level must be checked before the emergency opera-
tion phase.
NOTICE
If the emergency operation mode is used, the risk transfers to
the operator (the Motorenfabrik HATZ does not accept liabil-
ity in this case).
▪ Immediately after the emergency operation phase, deter-
mine the cause of the fault.
▪ Have the Hatz service station supply the emergency start
lever with a new lead seal.
91Operator's Manual
Page 92
Faults 1B20, 1B27, 1B30, 1B40, 1B50
Overview
1 Fuel shut-off valve (option)
2 Emergency start lever
Procedure
Step Activity
1 Using suitable pliers, turn the emergency start lever (2) coun-
terclockwise by at least 90° (seal wire tears).
The emergency start lever is now located in the start position,
and the fuel shut-off valve (1) is mechanically unlocked.
2 Start the engine with the starter or recoil start (see chapter 7.4
Starting the engine, page 37).
3 Turn the emergency start lever back to the stop in a clockwise
direction. Otherwise, it will not be possible to switch off the machine using the starting key.
92
Operator's Manual
HATZ
Page 93
1B20, 1B27, 1B30, 1B40, 1B50 Storage and disposal
10 Storage and disposal
10.1 Storing the machine
Safety notes
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
HATZ
CAUTION
Danger of environmental damage from spilled fuel.
Do not overfill the fuel tank and do not spill fuel.
▪ Collect any leaking fuel and dispose of it according to local
environmental regulations.
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in chapter 3 Safety, page 7.
93Operator's Manual
Page 94
Storage and disposal 1B20, 1B27, 1B30, 1B40, 1B50
Storing the machine for a lengthy period
Take the following measures if you intend to take the machine out of service
for a lengthy period (3-12 months):
Step Activity
1 Drain the fuel tank until it is nearly empty and fill with FAME*-
free fuel. Operate the engine for a few minutes so that only
FAME-free fuel is still in the fuel system.
2 Change the engine oil (see chapter 8.2.4 Change the engine oil,
page 60).
3 Change the fuel filter (see chapter 8.2.11 Changing the fuel fil-
ter, page 78).
4 Let the machine cool down.
5 Remove the battery in accordance with the Operator's Manual
for the machine and store at ambient temperature. Comply with
the local regulations as well as the regulations of the battery
manufacturer for the storage of batteries.
6 Close and seal all engine openings (air intake openings, air out-
let openings and the exhaust gas opening) so that no foreign
bodies can enter, but a small amount of air can still be exchanged. This avoids condensation.
7 After the machine has cooled down, cover it to protect it against
dust and store it in a dry and clean place.
94
*FAME = Fatty Acid Methyl Ester
Ambient conditions during storage
▪ Max. permissible storage temperature: -25°C to +60°C
▪ Max. permissible humidity: 70%
▪ Protect the engine from direct sunlight
Recommissioning
Step Activity
1 Remove all covers.
2 Check the cables, hoses and lines for cracks and leak tightness.
3 Check the engine oil level.
4 Install the battery in accordance with the Operator's Manual for
the machine.
Operator's Manual
HATZ
Page 95
1B20, 1B27, 1B30, 1B40, 1B50 Storage and disposal
The brand new engine can normally be stored for up to 12 months. The protection lasts up to approx. 6 months at very high humidity and with sea air.
For storage periods of more than 12 months, please contact the nearest
Hatz service.
10.2 Disposing of the machine
Disposal information
Dispose of the machine (including machine parts, engine oil and fuel) according to the local disposal regulations and the environmental laws in the
country of use.
Because of the danger of possible environmental damage, only permit an
approved specialist company to dispose of the machine.
NOTICE
When the machine has reached the end of its lifecycle, ensure
that it is disposed of safely and properly, especially parts and
substances that can be dangerous to the environment. These
also include fuel, lubricants, plastics, and batteries (if present).
▪ Do not dispose of the battery with the household trash.
▪ Dispose of the battery at a collection point for possible recy-
cling.
HATZ
95Operator's Manual
Page 96
Installation declaration 1B20, 1B27, 1B30, 1B40, 1B50
Extended Declaration of Incorporation
EC Machinery Directive 2006/42/EC
The manufacturer: Motorenfabrik Hatz GmbH & Co.KG
Ernst-Hatz-Straße 16
D-94099 Ruhstorf a. d. Rott
hereby declares that the incomplete machine: product description: Hatz diesel engine
Type designation and as of serial number:
1B20=10034; 1B20V=11124; 1B20R=14413; 1B27=12514;
1B30=10129; 1B30V=11220;
1B40=11019; 1B40V=11719;
1B50=12416; 1B50V=12616;
satisfies the following basic safety and health protection requirements in acc. with Annex I to the
above-mentioned Directive.
- Annex I, General principles no. 1
- Nr. 1.1.2., 1.1.3., 1.1.5., 1.2.1., 1.2.2., 1.2.3., 1.2.4.1., 1.2.4.2., 1.3.1., 1.3.2., 1.3.3., 1.3.4.,
1.3.7., 1.3.9., 1.4.1., 1.5.1., 1.5.3., 1.5.8., 1.5.9., 1.6.1., 1.6.2., 1.6.4., 1.7.
All relevant basic safety and health protection requirements down to the interfaces described
in the operating manual
in the enclosed data sheets
in the enclosed technical documents
have been complied with.
The special technical documents in acc. with Annex VII B of the Directive 2006/42/EC have been
prepared.
Conformity with the provisions of the following, other EC Directives, i.e.
- 2004/108/EG Electromagnetic Compatibility (EMC), dated 15.12.2004
The following standards have been used (completely or partially):
- EN 1679-1: 092011 - EN ISO 12100-1: 032011 - EN ISO 13857: 062008
- EN 60204-1: 062007
The Operating Manual has been enclosed to the incomplete machine and the Assembly Instructions
have been provided to the customer electronically together with the order confirmation.
Commissioning has been prohibited until it has been established, if applicable, that the machine into
which the above-mentioned incomplete machine is to be incorporated, satisfies the provisions of the
Machinery Directive.
Wolfgang Krautloher / see "Manufacturer"
Name / address of EC documentation officer
15/02/2016 Krautloher / Directives official
Date Signature and information on the undersigned Signature
11 Installation declaration
96
Operator's Manual
HATZ
Page 97
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Page 98
Motorenfabrik Hatz GmbH & Co. KG
Ernst-Hatz-Str. 16
94099 Ruhstorf a. d. Rott
Deutschland
Tel. +49 8531 319-0
Fax. +49 8531 319-418
marketing@hatz-diesel.de
www.hatz-diesel.com
CRE ATI NG POW ER SOL UTI ONS .
0000 433 802 11 - 05.2016 - 3
Printed in Germany
EN
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