Hatz Diesel 1B20V, 1B40W, 1B50V, 1B30V, 1B40V Original Instruction Book

33

1B20V
1B30V
1B40V
1B40W
1B50V
1B50W

Translati on of the

ORIGINAL INSTRUCTION BOOK

0000 433 802 77- ENG- 01.11- 0.1

Printed in Germany

A new HATZ Diesel engi ne - working for you

This engine is int ended only f or the purpose determined and tested by the manufacturer of the
equipment in whi ch it is i nstall ed. Using it in any other manner contr avenes the intended purpose.
For danger and damage due to this, Motorenfabrik HATZ assumes no liability. The risk is with the
user only.
Use of this engine in the intended manner presupposes compliance with t he maintenance and repair
instructions laid down for it. Noncompliance leads to engine breakdown.
Please do not fail to read this operating manual before starting the engine. This will help you to avoid
accidents, ensure that you operate the engine correctly and assi st you i n complyi ng wit h the mainte­nance intervals i n order t o ensure long-lasting, r eliable performance.
Please pass this Instruction Manual on to the next user or t o the fol lowi ng engine owner.

Always have service work performed by qualified specialists. To this effect, we recommend that you
consult one of the 500 HATZ servi ce stati ons. There, your engine is repai red by staff who constantl y
undergo tr aining and who use both original HATZ spare parts and HATZ tools. The world-wide HATZ
service network i s also avail able to you for consult ation and spare part s supply.
For the address of your nearest HATZ service station, please refer t o the attached list or the internet
under: www.hatz-di esel . com

The installation of inappropriate spare part s may cause problems. We cannnot accept any li ability for
damage or consequent ial damage resulting therefrom.
Thus, we recommend that you use ori gi nal HATZ spare parts. These parts are manufactured fol low­ing the strict HATZ specifications and ensure, thanks to their perfect f it and functi on, maximum oper­at ing reliabi l i t y. For the r ef er ence number, p l ease c on su l t the at t ached spare par t l i st or t he i n t er net
under: www.hatz-di esel . com. Please take the complete spare par ts ki ts i n Table M00 into account.

We r eserve the ri ght t o make modifications in the course of technical progress.

MOTORENFABRIK HATZ GMBH & CO KG

1

Page

1. Important safety notes
when operat ing the engi ne 3

2. Descri pti on of the engi ne 5

3. General notes 6

3.1. Technical data 6

3.2. Tr ansport 7

3.3 Notes on install ation 7

3.4. Load on engine 7

3.5. Type plate 7

4. Operation 8

4.1. Prior to first-time start-up 8

4.1.1. Engine oil 8

4.1.2. Fuel 9

4.2. Starting 10

4.2.1. Preparations for starting 10

4.2.2. Recoil start for versions without
elect r i c starter 11

4.2.3. Recoil st art for versions with
elect r i c starter 12

4.2.4. Electric starter 12

4.3. Stopping t he engine 14

5. Maintenance 16

5.1. Maintenance chart 16

5.2. Maintenance every 8 – 15
operating hour s 18

5.2.1. Checking engine oil level 18

5. 2. 2. Check ai r int ake ar ea f or
combusti on and cooling 18

5.2.3. Check air cl eaner maintenance
indi cator 18

Page

5.3. Maintenance every 250
operating hour s 19

5.3.1. Changing engine oil 19

5.3.2. Checking and adjusti ng
val ve cl ear ances 19

5.3.3. Cleaning the ai r cleaner zone 21

5.3.4. Checking scr ew connections 21

5.3.5. Cleaning the exhaust mesh inl et 21

5.4. Maintenance every 500
operating hour s 23

5.4.1. Renewing f uel filter 23

5.4.2. Air cleaner maintenance 23

5.5. Maintenance every 1000
operating hour s 25

5.5.1. Cleaning the oil filter 25

5.6. Servi cing: once a year 27

5.6.1. Draini ng the fuel tank 27

6. Malfunctions – causes – remedi es 28

7. Work on the el ectrical system 32

8. Storage out of use 32

Declar ati on f or Incorporati on 33

2

Contents

This symbol i dentifies impor tant safety precautions.
Please comply wit h these most carefully in order to avoid any risk of inj ury to persons or
damage to materials.
General legal requir ements and safety regulati ons issued by the competent authorities or
industrial accident insurers must also be complied with.

1. Important safety notes when operati ng the engi ne

HATZ diesel engines are effi cient, strong and durable. For this reason they are fr equently installed on
equipment used for commercial pur poses.
The manufacturers of such equipment must observe any relevant equipment safety r egulations when
the engine forms part of an overall syst em.
A few general points concerning operati ng safety should none the less be noted.
Depending on the engine’s operati ng and installation condi tions, equipment manufacturers and their
users may have to fit safety or protective devices in order to prevent impr oper use. Examples:

– Exhaust system components as well as the surface of the engine will naturall y be hot and must not

be touched while the engine is running or until it has cooled down aft er being stopped.

– Incor rect wi ri ng or i mproper operati on of the electr ical syst em may cause sparking and must there-

fore be avoided.

– Provide prot ection against cont act wit h rot ating part s once the engine is connected to t he driven

equipment or machine.
HATZ protective guar ds are available for the belt dr ive of t he cooling f an and alternator dri ve
systems.

– Always observe the start -up i nfor mation in the operating i nstructions before start ing the engine:

thi s i s parti cul arl y i mpor tant when starti ng an engi ne wi th the recoil start er !

– Mechanical st arting devices should not be operated by children or persons deficient in physical

str ength.

– Check that all safety devices are in place before starting the engine.

– Ensure that operation, maintenance and repair of the engine are undertaken by suitably t rained

personnel only.

– Pr otect t he starter k ey ag ainst unau thorised u se.

– Do not run t he engine in cl osed or badly ventil ated rooms.

Do not breath in emissi ons – danger of poisoni ng!

– Also fuel and lubricants could contain poi sonous components. Please follow the instructions of the

mineral oil producer (safety data sheet s).

3

Important safety notes when operati ng the engine

– The engine must be stopped befor e perf ormi ng any maint enance, cleaning- or r epair work.

– Stop the engine befor e refil ling the fuel t ank.

Never refuel near a naked flame or sparks which could start a fir e. Don’t smoke. Don’t spill fuel.

– Keep explosive mat erials as well as fl ammable materials away from t he engine because the exhaust

gets very hot during operati on.

– Wear close-fitting cl othi ng when working on the engine while it is running.

Please don’t wear necklaces, bracelets or any other things which you could get caught wi th.

– Please pay attention to all advice- and warni ng sti ckers placed on the engine and keep t hem in legi-

ble condit ion. In case a label has come off or is no longer clear ly legible, it must be replaced imme­diately. To thi s effect, please contact the HATZ servi ce stat i on in your area.

– We accept no liability f or damage result ing f rom i mproper modi fi cations t o the engine.

Regular maintenance in accordance with the details given in these operati ng instructions is essential
to keep the engine in good working order.

When in doubt, consult your local HATZ servi ce stat i on before starting the engine.

4

2. Descripti on of the engi ne

5

Fi g 1

1 Fuel tank cap
2 Recoil starter
3 Dr y-t y pe ai r cl eaner
4 Intake opening for cooling and

combusti on air
5 Voltage regulator
6Starter motor
7 Noise insul ating hood
8 Li fting lug

9 Engine shutdown pin
10 Speed control lever
11 Oil filler pipe
12 Oil filter
13 Oil drain plug
14 Dipstick
15 Exhaust mesh insert
16 Exhaust silencer
17 Type plate

3. General notes

3.1. Techni cal data

1)

These val ues ar e i nt ended as an ap pr oxi mate g ui de. Th e max. mar king o n t he di pst i ck is t he
determining factor, Fig. 7.

2)

Depending on model (see maintenance charts, chapter 5.1)

3)

Exceeding these limits causes engine breakdown.

Tightening torques

Item Nm

Oil drain plug 50

Ty p e 1B20 V 1B30 V 1B40 V/ W 1B50 V/ W

Desi g n Air-cooled four-stroke diesel engine

Combustion system Direct injection

Number of c yl i nder s 1 1 1 1

Bore/stroke mm 69 / 65 80 / 69 88 / 76 93 / 76

Di spl ac ement

cm

3

243 347 462 517

Lubricating oil capacity l, approx.

0.9

1)

1.1

1)

1.5

1)

1.5

1)

Difference between
„max.“ and „min“ levels l, approx. 0.5

1)

0.5

1)

0.8

1)

0.8

1)

Lubricating oil consumption
after a running-in period

max. 1 % of f uel consumpti on at ful l l oad

Lubricating oil pressure
(oil temper ature 100 °C) approx. 2.5 bar at 3000 r.p.m.

Direction of rotation,
power take-off end counterclockwise

Val ve clearance 10 - 30 °C
Inlet and exhaust valve

mm

0.20 0.10 0.10 0.10

or automatically

2)

Max. angle fr om vertical in any
direction (continuous operation) 25°

3)

Weight (incl. f u el t ank , air- cleaner,
exhaust si lencer, recoi l starter and
electric starter)

kg

approx. 35 42

1B40 V : 55
1B40 W: 57

1B50 V: 56
1B50 W: 58

Battery capacity min / max 12 V - 36 / 60 Ah 24 V - 24 / 44 Ah

6

3.2. Tr ansport

A suspension l ug „ 8“ is provided as

standar d equipment, so that t he engi ne
can be l ifted safel y, chap. 2. It is not sui tabl e
or appr oved for lifting the compl ete equipment
to whi ch the engine is attached.

3.3. Notes on i nstallati on

If you have an engine which is not yet installed
in a machine and still has to be installed, make
sure that the Assembly Instructions for HATZ
Diesel Engines are complied with prior to inst al­lation. These Assembly Instructions contain im­portant information about safe assembly of t he
engine and are available fr om your t he HATZ
ser vice cent er in your ar ea.
Pending compl ete instal l ati on, the engine
must not be started !
Moreover, we would like to point out that i n thi s
case, commissioning of the machine is also pro­hibited until it has been veri fied that the machine
into which this engine is t o be incorpor ated
complies with all the safety precautions and reg­ulations provided by law.
Refer also to the Declar ati on for Incorporati on
at the end of these Operati ng Inst ruct ions.

2

The permitted loads and elements

on the speed adj ust i ng lever and the
engine shutdown pi n shoul d be obser ved as an
excess can l ead to damage t o the cont acts and
inner governor parts, Fig. 2.

3.4. Load on engi ne

Operating the engine for a lengthy period of f­load or at ver y low loads can affect i t s r unnin g
quality. We therefore recommend a minimum
engine load of 15 %. If operated at such low
loads, it is best t o operate the engine at a signifi­cantly hi gher load for a short period before
switching it off.

3.5. Type plate

3

The type plate is pl aced on the noise insulating
hood (Fig. 1) and includes the following engine
information:

➀ engine type
➁ code (only f or special equipment)
➂ engine number

(also st amped on crankcase, Fig. 4)

➃ max. engine speed.

For any offer as wel l as spare parts orders i t i s
necessary to menti on these data (also see spare
parts list, page 1).

➀

➁

➂

➃

7

4

Engine serial number on cr ankcase.

4. Operation

4.1. Before start i ng up for the

first time

Engines are normally suppl ied dry, i.e. not con­taining fuel or oil.

4.1.1. Engi ne oi l

Oil qualit y
Qualified are all trademark oils which fulfil at
least one of the fol lowi ng specifications:

ACEA – B2 / E2 or more signi ficant
API – CD / CE / CF / CF-4 / CG-4 or more
significant.

If engine oil of a poorer qualit y is used, reduce
oil change intervals t o 150 hours of operation.

Oil viscosi ty

5

Please select the recommended viscosity de­pending on the ambient temperature at which
the engine is operated.

Inappropri ate engine oil may shorten the
engine’s ser vice life si gni ficantl y.

-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/40

10 W

/30

15 W /4 0

30

40

122

10 W

8

When adding oil or checking the oil level , the
engine must be horizontal.

6

– Remove oil filler screw „1“ and dipstick „2“.

7

– Add engine oil up to t he MAX mark on dip-

sti ck.
Lubri cating oil capacity: see Chapter 3.1.

– Insert the oil fi ll er screw and tighten it (hand-

tight only).

At te nt i on !
If the engine is operated while the oil level is
below the min. mark or above the max. mark,
it can cause damage to the engine.

4.1.2. Fuel

Stop the engi ne bef ore r efi l l i ng the fuel

tank. Never r efuel near a naked fl ame
or sparks which could start a fire.
Don’t smoke. Use only pur e fuel and clean
fi l l i ng equi pment. Take care not to spill f uel .

All diesel oil s which sati sfy t he foll owing specif i­cat i ons are su i tabl e:

EN 590 or
BS 2869 A1 / A2 or
ASTM D 975 -1D / 2D

Important !
The use of fuel s of different specifi cati ons
requi res the prior written consent of the HATZ
headquarters.

8

– Before the first start or if the fuel tank has

been run dry, completely fill the fuel tank with
di esel. The bl eedi ng of the f uel system i s auto­matically.

9

At temperatures below 0 °C, winter-grade fuel
should be used or paraffin added to the fuel well
in advance.

4.2. Starti ng

Do not run t he engi ne in closed or

badly venti l ated rooms – danger of poi­soning! Before starting the engi ne, ensure that
no-one i s i n the danger area close to the en­gine or equi pment, and that all protecti ve
guards are fi tted.

4.2.1. Preparati ons for starting

If possible, disengage the engine fr om any
driven equipment.
The auxiliary equipment should always be placed
in neutral.

Recoil starter

9

Check the st arter rope for chafi ng and,

if necessar y, r epl ace it.

A damaged rope may break duri ng

starti ng, and cause i nj ury.

0000 053 338 01

Lowest ambient

temperatu re when

start ing, in °C

Paraffin content for:

Summer Wint er

f uel f uel

0 up to –10 20 % –
–10 up to –15 30 % –
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %

10

– Set speed control lever „1“; First of all put the

lever in STOP-position and then either to
1/2 START or max. START posi ti on, as desir ed
or necessary.
Starting at a l ower speed w i ll hel p to pr event
exhaust smoke.

– Now, the engi ne is ready for starting.

Important !
After long-time standstill (approx. 6 months or
even longer) or first operation, operate engine
with low adjust ed speed and without load for
approx. 20 sec. after start . This measure assures
a lubrication of all bearings befor e increasing
speed and l oad .
It also prevents an insufficient l ubrication.

10

11

Never use starti ng sprays !

4.2.2. Recoil start for versions without
electri c starter (ti l l -6 °C)

– For starting preparations, see Chapter 4.2.1.

Starting procedure

12

– Pull t he starti ng cable out by the handle until

you feel a slight resistance.

– Let the cable run back; in this way the entire

length of the start ing cable can be used to
start the engine.

– Devices which are not securely fastened

should be restr ained with t he foot.

13

– Grip the handle with bot h hands.

14

– Commence pul li ng the starting cable vigor ous-

ly and at an increasing speed (do not jerk it
violently) until the engine starts.

11

Not e:
If after several attempts of starting the exhaust
begins to emi t whi t e smoke, m ove the speed
control lever to t he STOP position and pull the
starting cable out slowly 5 times. Repeat the
start ing pr ocedure, Chapter 4.2.1.

4.2.3. Recoil start for versions with
electri c starter (ti l l -6°C)

The r ecoi l st ar t er at engines wi t h el ectric st ar t i s
an emergency starting device without decom­pression automatic.
Therefor e, attenti on has to be paid to the exact
starti ng procedure as ment ioned below.

– Pr epare the eng ine f or st ar ting;

see Chapter 4 .2.1.

– Pull out the handle with the cord slowly until

compression resistance is clearly felt; Fi g. 12.

– Continue to pull slowly but with great er force

until the resistance becomes noticeably less
(compr ession overcome).

– Now let the cord r un back - the engine is in

the corr ect start ing posi ti on.

In this way the engine can be accelerated
through about one and a half revolutions with
the starting cord, to overcome compression re­sist ance and achieved the required momentum
for starting.

– Support equipment with t he foot if it i s too

light in weight or liable to tip over.

– Take hold of the handle wit h both hands;

Fig. 13.

– Pull t he starti ng cord up forceful ly and at an

increasi ng speed ( but do not j er k it ) - t he en ­gine should t hen start; Fig. 14.

Not e:
In the case of engines with automati c el ectr ical
shutdown syst em (see next chapter) , first
act u at e t he s t ar t er sw i t ch from posi ti on 0 t o
positi on I, then perform a recoil start within the
following 12 seconds. If the engine does not r un
after 12 seconds, this means that t he electrical
system blocks t he fuel supply to the injection
pump.
In this case, the engine cannot be started.
As a solution, turn the starter key back to posi ­ti on 0, t hen turn i t t o posi ti on I again. Now, start
the engine withi n the fol lowi ng 12 seconds.

4.2. 4. Electric starter

– For starting preparations, see Chapter 4.2.1.

15

– Insert the key to i ts st op and turn it to

position I.

– Battery charge tell tale „2“ and oil pressure

warning „3“ must light up.

– Tur n start key to positi on II.

– As soon as t he en gi ne runs , releas e t he start

key. It must return to posi tion I by itself and
remain in t his posi ti on duri ng operation.

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12

– The battery charge tell tale and oil pr essure

warning must go out immediately after st art­ing. Indicator light „ 1“ is on when the engine
is in operation; Fig. 15.

– The engine temper ature displ ay „4“ (additional

equipment) lights up if the temperature at the
cylinder head becomes t oo high.
Swit ch off the engi ne and t race and el i mi ­nate t he cause of t he probl em, chap. 6.

– Always turn the start key back to posi t ion 0

before re-st arti ng the engine. The repeat lock
in the ignition lock prevents the starter motor
from engaging and possibly being damaged
whil e the engine is still running.

Not e:
Start f or max. 30 seconds. If the engine does
not run after this time, turn starter key back to
positi on 0 and eliminate the cause, Chapter 6.

Preheati ng devi ce wi th automatic heati ng
ti mer (additional equipment)

The preheat ing l ight „5“ lights up additionally at
temperatures below 0° Celsi us (Fig. 15).

– After the light has gone out, start the engine

without delay.

Fuel shut-off val ve, st op sol enoi d

(additional equipment)

16

As soon as the starting key is at Positi on I,
fuel shut-off val ve „ 1“ is el ectr i cally rel eased.
The fuel feed to the injection pump is then open
and the engine is ready t o start .
When the engine is running, turning the starting
key to posi ti on 0 cl oses the shut-off val ve and
interrupts the fuel supply to the injection pump,
so that t he engine stops; Chapter 4.3.
This shut-off valve is also used for the automatic
electrical shutdown system.

Emergency start

If the shut-off valve is blocking the fuel suppl y
as a result of an electrical faul t and the engi ne
therefore cannot be started, an emergency start
can be attempted.
Proceed as follows for this:

– For emergency starti ng, turn the lever at fuel

shut-off solenoid „ 2“ anti-clockwi se by at l east
90° using suitable pliers. The lead seal wi re
will break of f.; Fig. 16.

13

– As soon as the emergency start lever is in the

start ing position, the electric start er or recoil
start er can be used; Chapter 4.2.2 and 4.2.3.
The oil level must always be checked before an
emergency start, as insufficient oil pressure
can lead to complete damage of the engine
within a very short time.

After this, the engine can only be
stopped wit h the start ing key in t he

emergency operating mode if the emergency
starting lever is first turned back clockwise to
the stop position.

Immedi at el y af t er a per i o d o f emer gency
running, ascert ain the cause of t he fault and
have it rectified; Chapter 6.
Have t he emer gen cy-st ar ting lever seal ed once
again by a HATZ service point.
When the automatic electrical shutdown system
is used, the emergency start described above
means that liability for risks must be accepted
by the operator (Motor enfabri k HATZ assumes
no liability) !
In case of difficulty contact the nearest HATZ
service poi nt .

Automati c el ectrical shutdown system

(additional equipment)

This is characteri zed by a brief f lashing of all
pilot lamps once t he starter key has been turned
to posi tion I (Fig. 15).

Important !
If the engine cuts out immediately after starting
or switches off by itself during operation, a
moni t or i ng el emen t in t he aut om atic shut d own
system has tri pped. The cor responding indicator
light (Fi g. 14, positions 2 - 4) will come on.
After the engine has stopped, the display contin­ues to glow f or about 2 mi nutes.
The el ectr i cal devic e t hen switches itsel f of f au­tomatically.
The display li ghts up again after t he start key
has been turned back to posi ti on 0 and then to
positi on I again.
Tr ace and el i mi nate the cause of t he operat i ng
faul t before trying to restart the engine
(see chapter 6.2.).

The display light goes out when the engine is
next started.

Even with automati c shutdown monitoring
the oi l l evel must be checked every 8 – 15
operating hours (Chapter 5.2.1.).

4.3. Stopping the engi ne

17

– Move the speed adjustment lever „ 1“ back

to t he STOP position. The engine cuts out .

14

Not e:
Engines wit h a fi xed lower i dl i ng speed cannot
be switched off using the speed adjustment
lever. See the paragraph entitled „Ot her ways of
switching off the engine“.

Other ways of swi tching off the engi ne

1. Fuel shut-off val ve, stop solenoid

(opt ional extra)

– Tur n igni tion key to the 0 posi ti on. The engine

cuts out , Fig. 19.

2. Stop pin (optional extra)

18

– Press the stop pin „ 2“ until the engine cuts out

(see also Fig. 17, pos. 2).

– Once the engine has cut out, release t he

pin „2“ and ensure that it returns to its initial
posit ion, Fig. 17.

05221301

19

Depending upon the model, the battery charge
indicator „2“ and oil pressure warning indicator
„3“ will come on again after the engine comes to
a stop.

– Tur n the key to posi ti on 0 and remove it.

All the indicator lights must go out.

Not e:
Failure to return the starter key to position 0
may result in the battery being totally
discharged.

If operation of the engine is inter-

rupted for any reason, or at the end of
the working day, the starter key should be kept
out of reach of unauthorised persons.

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15

5. Mai ntenance

Only carr y out mai ntenance work wi t h the engi ne swi t ched off.

Observe al l relevant l aws and regulati ons governing the handl i ng and di sposal of used oil,
fi l ters and cl eani ng agents.
Protect the starting key against unauthori sed use.
On engines with an el ectri c starter, di sconnect the batter y’s negati ve ter mi nal.
When maintenance work has been compl et ed, check that all tool s have been removed from the
engine and all protecti ve guards fi tt ed agai n.
Before starting the engi ne, ensure that there are no persons in the danger area cl ose to the en­gine or equi pment.

5.1. Mai ntenance chart

Mai ntenance i nterval Maintenance work requi red Chap.

16

Every 8 – 15
operating hour s,
or befor e each daily
start -up

Check oil level.
Check combustion and cooli ng air intake zone.
Check ai r-cl eaner maintenance indicator.

5.2.1.

5.2.2.

5.2.3.

Every 250
operating hour s

Change engine oil.
Check and adjust valve clearances. (Not appli ca­bl e with aut omat i c s elf adj ust ing val ve c l earance
models, see next page)
Clean cool i ng air area.
Check screw connections.
Clean mesh i nsert f or exhaust.

5.3.1.

5.3.2.

5.3.3.

5.3.4.

5.3.5.

Every 500
operating hour s

Change fuel filter el ement .
Dry-t ype air cleaner maintenance.

5.4.1.

5.4.2.

Every 1000
operating hour s

Clean the oil f i l t er.

5.5.1.

Once a year Siphon water out of fuel t ank.

5.6.1.

8-15

250

500

1000

Depending whether the engine is equipped with
or without automatic valve clearance adj ustment
one of the illustrated maintenance plans is in­cluded. This label should be af fi xed to the engine
or equipment in an easil y visi ble position. The
maintenance chart governs t he maint enance in­tervals.

On new or reconditi oned engi nes, after the
fi rst 25 operati ng hours, always

– Change engine oil , Chapt er 5.3.1.

– Check valve cl ear ances an d ad just if

necessary, Chapter 5.3.2.

– Examine screw connecti ons, chapter 5.3.4.

Do not ti ghten the cyl i nder head fastening.

If the engi ne i s not used frequentl y, change the
engine oil aft er 12 months at the l atest, regard­less of the actual number of hours it has been i n
operation.

17

Model wi thout automatic valve clearance adj ustment.

Model wi t h automati c val ve cl ear ance adj ust men t.

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

0000 052 502 02

= 1h

max
OIL

500h

250h

IN

EX

max

AUTOM.

5.2. Mai ntenance every

8 – 15

operating hours

5.2.1. Checki ng engi ne oi l l evel

To check the oil level, the engi ne must be
standing l evel and be switched off .

– Remove any di rt from the oil dipstick area.

20

– For oil level inspection, remove the dipstick

and wipe it dr y using a lint-free, clean pi ece of
cloth; then insert it to its st op and pull i t out
agai n .

– Check the dipsti ck oil level and, if necessary,

add oil to the max. mark, Chapter 4.1.1.

At te nt i on !
If the engine is operated while the oil level is
below the min. mark or above the max. mark, i t
can cause damage to the engine.

5.2.2. Check air i ntake area for

combusti on and cool i ng

Heavy contamination i s an indication that i n­creased dust accumulation necessitates a
correspondingly shor ter maint enance interval,
Chapter 5.3.3. and 5.4.2.

21

– Check air intake points „1“ for severe blockage

due to leaves, heavy dust accumulati on etc.,
and if n ecessar y cl ean t hem.

5.2.3. Check air cleaner mai ntenance
i ndi cator (opt ional extra)

Mechanical servi ce i ndi cator

22

– Increase the speed of the engine briefly to the

maximum. If the rubber bel l ows shri nks and
cover s the green ar ea „ 1“ , t he air cl eaner sys­tem should be serviced, Chapter 5.4.2.
Under dusty condit ions, check the rubber
bellows several times per day.

18

5.3. Mai ntenance every

250

operating hours

5.3. 1. Changi ng engi ne oi l

The engine must be standing level and be
switched off.
Only change the oil when the engine is warm.

Danger of scal di ng from hot oil !
Tr ap the ol d oi l and di spose of it i n

accordance wi th local legi sl ation.

23

– Take out oil drain pl ug „ 1“ and al low t he oil t o

drain out .

– Clean the oil drain pl ug „ 1“, fi t a new washer

„2“, insert and tighten.

– Add engine oil , Chapt er 4.1.1.

5.3.2. Checking and adjusti ng val ve
cl earances

Rem ar k:
Following steps are inapplicable in case equip­ment is with automatic tappet clearance com­pensation. Identification characteristic is mainte­nance plan, chapter 5.1.

Only carr y out adjustments when the engine is
cold ( 10 - 30 ° C).

24

– Remove air cleaner cover.

25

– Remove noise insulating hood.

19

– Remove any contamination adher ing t o the

cover for the cylinder head.

26

– Remove screws „1“ and take off the cylinder

head cover wit h gasket „ 2“ .

27

– Remove rubber cap from the inspection hol e

cover.

– Tur n the engine over i n the normal di rection

of r otati on unti l t he valves are in the overlap
posit ion (exhaust valve not yet closed, inlet
valve starts to open).

– Tur n the crankshaft t hrough 360° in the

normal di rection of rotation and align exactly
to the OT-marking, Figure 27.

28

– Chec k v al ve c l ear anc es w i t h f eel er g auge „ 1“ .

For the setting, refer to Chapter 3.1.

– If valve clearances require adjusting, sl acken

off screw „2“ and turn hex nut „3“ until feeler
gauge „1“ can be pulled thr ough with just
slight resistance when screw „ 2“ is r etight ­ened .

– Fit cover for cylinder head and ti ghten evenly,

always using a new gasket.

– Re-attach parts previously r emoved from en-

gine.
Do not forget: r eplace the rubber cap at the
inspection hole cover.

– Carry out a brief test run, then check the cover

for leaks.

20

5.3.3. Cl eani ng cool i ng ai r area

The engine must be swi tched of f and
cooled down befor e cleaning !

– If severely contaminated, clean the cooling fins

on the cyli nder and cylinder head, and also the
fan blades in the flywheel. If necessary, con­tact your local HATZ servi ce station.

5.3.4. Checking screw connections

– Check the tight ness of all t hreaded connec-

tions and take up slack if necessary, provided
that t hese can be reached during maintenance
work.
Do not ti ghten the cyl i nder head bolts.

29

The adjust ing screws at the engi ne

governor and on the i nj ection system
are seal ed wi th lacquer and are not to be
ti ghtened or adj usted.

5.3. 5. Cleaning the exhaust mesh i nl et

Exhaust system components wi l l

naturally be hot and must not be
touched whi l e the engine is runni ng or unti l i t
has cool ed down aft er bei ng st opped.

30

– Release hex. nut and remove exhaust mani-

fold.

31

– Remove hex. nut and clip, t hen pull strainer

insert out.

21

32

Risk of injury!
Wear protecti ve gl oves.

– Eliminate deposited matter from the strainer

insert using a suitable steel brush.

– Subsequently, check the strainer i nsert for

cr acks or br eaks; if necessar y, r epl ace.

– Remount the strainer insert and the clip.

33

– Screw on hexagon nut „1“ by approx. 1 turn.

34

– Insert exhaust manifold with hoop „ 2“ into

hole, them pull outwards again so that t he
hoop is r etained.

– Tighten the hexagon nut fully.

2

22

5.4. Mai ntenance every

500

operating hours

5.4. 1. Renewing fuel fi l t er

The maintenance intervals for the fuel pump
filter are dependent upon the puri ty of the diesel
oil being used and, if necessary, may have to be
reduced to 250 hours.

When worki ng on the f uel system, do
not expose i t to naked f lames; do not
smoke.

Impor tant !
Keep the enti re area cl ean so that no di rt
reaches t he fuel . Fuel particles may damage
the i nj ection system.

35

– Open tank cap and pull out fuel f ilter from tank

with cord.

36

– Pull fuel supply line „1“ off fuel filter „2“ and

insert new filter.

– Fit the fuel filter again and close the tank cap.

Bleeding of the fuel injection system takes
pl ace aut om atical l y.

5.4.2. Air cl eaner maintenance

The filter cart ri dge should only be cleaned when
the maintenance lamp lights at maximum speed,
chap. 5.2.3.
However, the fi lter cartridge should always be
replaced after 500 operating hour s at the latest.

23

37

– Remove the air cleaner cover.

38

– Unscrew and remove knurled nut „ 1“ and take

of f ai r cleaner el ement „ 2“ .

– Clean t he fi l t er comp artment and t he cover.

Dirt and other for eign bodies must not be
allowed to enter the engine’s air inlet points.

39

– On versions with a mechanical air cleaner

service indi cator, check the condition and
cl eanli ness of val ve pl ate „ 1“ .

– The filter cart ri dge should either be renewed

or, depending upon t he degree of cont amina­tion, cleaned, or checked, as foll ows:

Cl eani ng the fi l ter cartridge

Dry contami nati on

40

– Use compressed air to blow through the filter

cartr idge fr om the insi de outwards, unt il no
further dirt emerges.

24

Impor tant !
The pressure must not exceed 5 bar.

Persons handling compressed ai r must
wear protective goggles. Never di rect

the j et to ani mal s, persons or yourself !

Moist or oily contami nation
Renew the filter cartridge.

Checki ng the f i l ter car tri dge

– Check filt er cartridge’s gasket surf ace „1“ for

damage, Fig. 40.

– Check t he fi l t er cart r i dge f or c racks or an y

other type of damage to t he paper filter by
holding it inclined towards the li ght or by
shini ng a light source thr ough it.

Impor tant !
The sli ghtest damage to the paper fi l ter rules
out i t being used any longer.

– Re-assemble the filter cartridge in the reverse

order of work.

5.5. Mai ntenance every

1000

operating hours

5.5.1. Cleani ng the oi l fi l ter

Cleaning of oil filter should be carri ed out
together wi th changing engine oil .

The engine must be standing level and be
switched off.

Danger of scal di ng from hot oi l !

Tr ap the ol d oi l and di spose of it i n

accordance wi th local legisl at ion.

41

– Loosen screw „1“ wi th approx. 5 rotati ons.

25

42

– Remove oil filter from housing.

43

– Use an air line to blow out oil filter di rt fr om

the insi de outwards.

Persons handling compressed ai r must
wear protective goggles. Never di r ect

the j et to ani mal s, persons or yourself !

44

– Check joint washer „1“ whether it is damage;

repl acement i f necessar y.

– Coat packing rings „1“ and „2“ slightly with oil

before assembly.

45

– Put in oi l filter and press unti l l imit stop.

– Check whether tension springs sit close to oil

filter with both ends „1“, before tightening
screw.

– Check the dipstick oil level and, if necessary,

add oil to the max. mark, Chapter 4.1.1.

26

5.6. Servicing: once a year

5.6.1. Drai ni ng the fuel tank

When worki ng on the f uel system, do
not expose i t to a naked flame;
do not smoke.

– Condensat ion f orms due to t emperature varia-

tions at the lowest points of the fuel tank.

The condensate must therefore be removed once
a year as f ol l ows:

46

– Fit a polyethylene tube ( diameter 4 mm,

length approx. 350 mm) to a commercial
syringe (20 ml or larger).

47

– Run the tube down to the bottom of the tank

and drain off the diesel oil/water mixture.
The specific gravity of water is heavier than
that of d i esel oil an d t herefor e a di stinct
dividing line should be visible.

– Repeat the procedure several times until the

transpar ent syr i ng e i s f ull o f di esel oi l on ly.

27

28

6. Mal functi ons – causes and remedies

Malfunctions Possible causes Remedy Chap.

6.1.
Engine does not
start, or not imme­diately, but can be
tur ned ov er easi l y
as usual.

At low
t emper atu res .

Speed control lever in stop or
idle position.
Engine shutdown pi n in STOP
position.

No fuel in t he injection pump.

Insufficient compression:

- Inco r rect valv e cl ear ance.

- Cylinders and/or piston rings
worn.

Inj ector not funct ioni ng.

Below starting threshold
t emper at ur e.

Equipment not disengaged.

Preheating system faulty
(opt ional extr a).

Fuel has inadequat e resistance
t o l ow t emper at ures.

Move lever to START position.
Move to operating posi ti on by
pulling the pin gently.

Add fuel .
Sys t emat i c al ly c hec k t h e ent i r e
fuel supply system: If still no
fault found,

- check engine feed li ne

- check f uel fi l t er

Check val ve clearances, adjustif
necessary.

See workshop manual.

See workshop manual.

Operate pr eheat er
(opt ional extr a).

Disengage engine from equip­ment, if possible.

See workshop manual.

Check whether clear (not turbid)
fuel emerges at the fuel line de­tached from the injection pump.
If turbid or separated - either
warm up the engine or drain the
complete fuel suppl y system.
Refill with winter-grade fuel to
which paraff in has been added.

4.2.1.

4.3.

4.1.2.

5.4.1.

5.3.2.

4.2.4.

4.1.2.

Malfunctions Possible causes Remedy Chap.

29

At low
t emper atu res

If equipped with a
stop solenoid or
automatic electri­cal shutdown sys­tem (addit ional
equipment)

6.2.
Engine fi res but
does not run.

With automatic
shutdown
(optional extra)

6.3.
Starter motor does
not operate or
engine does not
turn over.

Starti ng speed below 400 rpm:

- Viscosity of oil too high.

- Battery charge too low.

Solenoid fault y and/or fault i n
t he el ec trical system.

Speed cont r ol l ever not moved
far enough towards „ START“.

Equipment not disengaged.

Fuel fi lter blocked.

One of the automatic shut ­down’s monit oring elements
has init iated a stop signal.
(See also Chapter 6.4.).

Faul t in t he elect r i cal syst em:

- Battery and/or other cables

incor rectly connected up.

- Cable connections loose

and/or oxi dised.

- Battery faulty and/or flat.

- Starter motor faulty.

- Faulty relays, monit ori ng

el ement .

Change lubricating oil and add
oil of the corr ect viscosity class.

Check the battery, if necessary
cont act a s er vi ce st at i on .

See workshop manual.

Move lever to „START“ position.

Disengage engine from equip­ment if possible.

Renew fuel filter.

Local i se t he moni t or i ng el emen t
responsible and clear the fault,
or cont act a HATZ service
station.

Check elect r ical syst em and its
component.
See al so the workshop manual.

5.3.1.

4.1.1.

7.

4.2.1.

5.4.1.

7.

Malfunctions Possible causes Remedy Chap.

30

6.4.
Engine cuts out of
its own accord
during operation.

With automatic
elect r i cal shut­down inst alled
(optional extra)

6.5.
Engine output and
speed both drop.

Fuel supply interr upted

- Tank has run empty.

- Fuel fil t er block ed.

- Aeration outlet restricted at

fuel t ank seal .

- Air in the fuel system.

Mechanical fault s.

One of the automatic shut ­down’s monit oring elements
has init iated a stop signal.

Monit oring element for :

- oil pressure too l ow

- engine temperature too hi gh

- def ect i ve altern ator.

Malfunction signal from over-

vo ltage an d p ol ar i t y rever sal
pr otect ion in vol tage r egul at or :

- Battery and/or other cable

connections i ncorr ectly con­nected.

- Cable connections l oose.

Fuel supply interr upted:

- Tank has run empty.

- Fuel f ilter blocked.

- Aerati on outlet restr ict ed
at fuel tank seal.

- Air in the fuel system.

- Speed control lever does not
remain in desir ed positi on.

Add fuel .
Change fuel filter.

Ensure adequte tank venting.
Check fuel sy st em for
penetration of air.
Check air vent valve.

Cont act a HATZ ser v ice stati o n.

Local i se t he moni t or i ng el emen t
responsible and clear the fault,
or cont act a HATZ service
station.

Check oil l ubri cation.

Check air cooli ng zone for
co nt ami nat io n.
See workshop manual.

Check elect r ical equi pm ent and
the components thereof.

Add fuel .
Change fuel filter.

Provide adequate tank breat hing.
Check fuel sy st em for
penetration of air.
Check air vent valve.

Lock the lever into position.

4.1.2.

5.4.1.

5.2.1.

5.3.3.

4.1.2.

5.4.1.

31

Malfunctions Possible causes Remedy Chap.

6.6.
Engine output
and speed fall,
black smoke
fr om exhaust.

6.7.
Engine becomes
very hot. Indicator
lamp for cylinder
t emper atu re
(optional extra)
comes on.

6.8.
Condensate outlet
from exhaust box.

Air cl eaner contaminated.

Val ve clear ances incorrect.

Inj ector not funct ioni ng.

Too much l ubri cating oi l in
engine.

Inadequate cooling:

- Contamination of entire
cooli ng air zone.

- Ai r duct panels not properl y
seal ed.

Operation over a longer period
wit hout load.

Clean or r en ew the ai r cleaner.

Adjust valve clearances.

See workshop manual.

Drain off lubr icating oil as far as
upper mark on dipst ick.

Clean cooling air zone.

Check cooling air deflector
pl at es and s haf t s for co mplete­ness and airt ight seal.

Run engine wit h a load of 70%
until the exhaust box gets dr y
agai n.

5.4.2.

5.3.2.

5.3.1.

5.3.3.

7. Work on the electri cal
system

Batteries generate explosive gases.
Keep them away fr om naked fl ame and

sparks whi ch coul d cause them to i gni te.
Do not smoke.
Protect eyes, skin and cloth agai nst the corro­sive battery aci d. Pour cl ear water over aci d
splashes immediatel y. In case of emer gency
call doctor.

Do not place any tool s on top of the bat ter y.
Always di sconnect the negative (–) pol e of the
battery bef ore wor king on the el ectri c devi ce.

– Do not confuse the posi ti ve ( +) and

negati ve (–) terminals of the battery.

– When fitting the battery, first connect up the

posi ti ve l ead, t hen the negati ve lead.
Negati ve terminal to earth = engi ne bl ock.

– When removi ng, fir st di sconnect the negative

lead, t hen the posit i ve lead.

– Always take care to avoi d short-ci rcuits and

earth (ground) contact of live cables.

– If malfunctions occur, f ir st of all check that

cabl e connecti ons make good contact.

– Replace a failed indicator light without delay.

– Do not remove t he i gni ti on key whi le the en-

gine is r unning.

– Do not di sconnect t he batt ery while the en-

gine is r unning. El ectric voltage peaks can
cause damage to electrical components.

– In case of an emergency start in manual

mode, leave the battery (which might be dis­charged) connected to the engi ne.

– For emergency operation without battery,

make sure that t he plug-and-socket connector
to the instr ument box is disconnected addi­tionally before the engi ne is start ed.

– Do not splash electrical device with water jet

or pressure jet duri ng engine cleaning.

– When carryi ng out weldi ng wor k on the en-

gine or equipment, fit the eart h cli p of t he
welding equipment as close to t he welding
point as possible and disconnect the batter y.
The connecting plug for the voltage regulator
must be removed.

The r el ev ant c i rcuit di agrams are enclos ed w ith
the engine if i t i s equipped with an electrical
system. Additional circuit diagrams can be
supplied to order.

HATZ assumes no liability for electrical systems
which was not carr ied out acc. HATZ circui t di a­grams.

8. Storage out of use

The new engi ne can normally be stor ed dry for
up to one year.
In very humid climates or coastal r egions, the
protective treatment is sufficient for up to about
6 months.
For longer peri ods of st orage, please contact
your nearest HATZ service station.

32

33

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.

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