HATZ Diesel 1D90 User Manual

33

1D 41.
1D 42.
1D 50.

1D 81.
1D 90.

0000 433 202 09 - ENG - 12.09 - 3

Printed in Germany

Translation of the

ORIGINAL INSTRUCTION BOOK

1

A new HATZ diesel engine is ready to work for you

This engine is intended only for the purpose determined and tested by the manufacturer of the
equipment in which it is installed. Using it in any other manner contravenes 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 the maintenance
and repair instructions laid down for it. Noncompliance leads to engine breakdown.
Please study this Instruction Book before you start the engine for the first time: it will help you to
avoid accidents, to operate the engine correctly, to perform maintenance work and to keep the engine
operating at full efficiency for a very long time.
Please pass this Instruction Manual on to the next user or to the following engine owner.

Always have service work performed by qualified specialists. To this effect, we recommend that you
consult one of the 500 HATZ service stations. There, your engine is repaired by staff who constantly
undergo training and who use both original HATZ spare parts and HATZ tools. The world-wide HATZ
service network is also available to you for consultation and spare parts supply.
For the address of your nearest HATZ service station, please refer to the attached list or the internet
under: www.hatz-diesel.com

The installation of inappropriate spare parts may cause problems. We cannnot accept any liability for
damage or consequential damage resulting therefrom.
Thus, we recommend that you use original HATZ spare parts. These parts are manufactured follow­ing the strict HATZ specifications and ensure, thanks to their perfect fit and function, maximum oper­ating reliability. For the reference number, please consult the attached spare part list or the internet
under: www.hatz-diesel.com. Please take the complete spare parts kits in Table M00 into account.

In the interests of technical progress we reserve the right to introduce modifications.

MOTORENFABRIK HATZ GMBH & CO KG

Page

1. Important notes on safe operation
of the engine 3

2. Description of the engine 5

3. General information 7

3.1. Technical data 7

3.2. Transport 8

3.3 Instructions for installation 8

3.4. Load on engine 8

3.5. Type plate 8

4. Operation 9

4.1. Before initial start-up 9

4.1.1. Engine oil 9

4.1.2. Oil bath air cleaner 9

4.1.3. Fuel 10

4.1.4. Mechanical oil pressure monitor 11

4.2. Starting the engine 12

4.2.1. Preparations for starting 13

4.2.2. Starting with the handle 14

4.2.3. Starting in cold weather 15

4.2.4. Electric starter 16

4.3. Stopping the engine 17

5. Maintenance 19

5.1. Maintenace summary 19

5.2. Maintenance every 8 – 15 hours
of operation 21

5.2.1. Check engine oil level 21

5.2.2. Check air intake point 21

5.2.3. Air cleaner blockage indicator 21

5.2.4. Checking cooling air zone 22

5.2.5. Checking the water trap 22

Page

5.3. Maintenance every 250 hours

of operation 23

5.3.1. Oilbath air cleaner maintenance 23

5.3.2. Changing engine oil, renewing
oil filter 24

5.3.3. Checking and adjusting
valve clearances 25

5.3.4. Clean the cooling air system 26

5.3.5. Checking threaded connections 27

5.3.6. Cleaning mesh insert in exhaust
silencer 27

5.4. Maintenance every 500 hours
of operation 28

5.4.1. Renewing fuel filter 28

5.4.2. Dry-type air cleaner maintenance 29

6. Malfunctions – Causes – Remedies 31

7. Work on the electrical system 35

8. Protective treatment 35

9. Declaration for Incorporation 36

2

This symbol draws attention to important safety precautions.
Please comply with them most carefully in order to avoid any risk of injury to persons or
damage to materials.
General legal requirements or safety regulations issued by the competent authorities or
industrial accident insurers are also applicable.

Contents

3

1. Important notes on safe operation of the engine

HATZ diesel engines are economical, strongly built and long-lasting. They are therefore frequently
chosen for commercially and industrially operated equipment and machinery.
Since the engine forms part of the finished equipment or machine, its manufacturer will take all the
applicable safety regulations into account.
Nevertheless, we give below certain additional comments on operating safety, and would recommend
you to note them carefully.
Depending on the manner in which the engine is installed and its intended application, the equipment
manufacturer or operator may have to attach additional safety devices and prohibit potentially hazard­ous aspects of operation, for example:

– Parts of the exhaust system as well as the surface of the engine are of course hot during operation

of the engine, but also when it is still cooling down after use, and must not be touched.

– Faulty wiring or incorrect operation of electrical equipment may lead to sparks forming, and must

be avoided as a potential fire hazard.

– Rotating parts must be shielded against accidental contact when the engine is installed in other

equipment or machinery.
Guards are available from HATZ to protect belt drives, cooling fans and generators.

– Before attempting to start the engine it is essential to have studied the starting information in the

Instruction Book; this is particularly important on engines started with a starting handle.

– Mechanical starting devices must not be used by children or persons of insufficient physical

strength.

– In order to benefit from the advantages of the starting handle with kick-back damping, it must be

used precisely as recommended in this Instruction Book.

– Before starting the engine, ensure that all the specified protective guards are in place.

– The engine must only be operated, serviced or repaired by persons who have received the appro-

priate training.

– Keep the starting handle and the key out of reach of unauthorized persons.

– Never run the engine in closed or badly ventilated rooms.

Do not breath in emissions - danger of poisoning!

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

mineral oil producer (safety data sheets).

4

Important notes on safe operation of the engine

– Stop the engine before performing any maintenance, cleaning- and repair work.

– Stop the engine before refuelling.

Never add fuel near a naked flame or a source of sparks.
Don’t smoke. Don’t spill fuel.

– Keep explosive materials as well as flammable materials away from the engine because the exhaust

gets very hot during operation.

– Wear close-fitting clothing when working on a running engine.

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

– Please pay attention to all advice- and warning stickers placed on the engine and keep them in legi-

ble condition. In case a label has come off or is no longer clearly legible, it must be replaced imme­diately. To this effect, please contact the HATZ service station in your area.

– Note that any unauthorized modification to the engine absolves its manufacturer from liability for

the consequences.

Regular servicing in accordance with the details provided in this Instruction Book is essential to keep
the engine operating reliably.

In case of doubt, always consult your nearest HATZ service station before starting the engine.

5

2. Description of engine

1D41 • 1D42 • 1D50 • 1D81 • 1D90 S / Z engines

1

2391 / 12 2391 / 7

1 Cooling air inlet
2 Dry-type air cleaner
3 Decompression lever
4 Stop lever
5 Cooling air outlet
6 Silencer (muffler)
7 Guide sleeve for starting handle
8 Cylinder head cover
9 Cold-start oil metering device

10 Suspension lug

11 Tank filler cap
12 Oil drain plug, governor housing
13 Oil drain plug, governor side
14 Speed control lever
15 Oil filler pipe and dipstick
16 Fuel filter
17 Oil filter
18 Type plate
19 Tank drain plug
20 Combustion air intake

6

Description of engine

Fully-encapsulated version

1D41C • 1D42C • 1D81C • 1D90 C engines

2

1 Capsule
2 Decompression lever
3 Cold-start oil metering device
4 Combustion and cooling air intake
5 Oil filter
6 Cleaning hatch
7 Side panels
8 Hold for starting handle
9 Suspension lug

10 Silencer (muffler), encapsul.
11 Cooling air outlet
12 Battery connection and central plug

for electrical system
13 Stop lever
14 Speed control lever
15 Oil drain plug
16 Oil filler and dipstick
17 Type plate

2392 / 1 2392 / 4

7

3. General information

3.1. Technical data

1)

These data are approx.-values. The max. mark on oil dipstick counts.

2)

Exceeding these limits causes engine breakdown.

Type 1D41. 1D42. 1D50. 1D81. 1D90.

Engine models S, Z, C S, Z, C S, Z S, Z, C S, Z, C

Mode of operation air-cooled four-stroke diesel engine

Combustion method Direct-fuel injection

Number of cylinders 1 1 1 1 1

Bore / stroke mm 90 / 65 90 / 70 97 / 70 100/85 104 / 85

Displacement

cm

3

413 445 517 667 722

Engine oil content without filter

with filter

approx. L

1.1

1)

1.2

1)

1.1

1)

1.2

1)

1.4

1)

1.5

1)

1.8

1)

1.9

1)

1.8

1)

1.9

1)

Volume of oil between
„max“ and „min“ marks

approx. L

0.4

1)

0.4

1)

0.5

1)

0.9

1)

0.9

1)

Consumption of lubrication oil
after running-in period

approx. 1 % of fuel consumption at full load

Engine oil pressure
Oil termperature 100 ± 20 °C

min. 0.6 bar at 850 r.p.m.

Direction of rotation
looking at the flywheel

counterclockwise

Valve clearance at 10 - 30 °C
Inlet
Exhaust

mm

0.10

0.20

0.10

0.20

0.10

0.20

0.10

0.20

0.30

0.30

Max. angle from vertical in any
direction (continuous operation)

max. 30°

2)

30°

2)

30°

2)

25°

2)

25°

2)

Weight (incl. fuel tank, air-cleaner,
exhaust silencer and electric starter)
Engine model S
Engine model Z
Engine model C

approx. kg
approx. kg
approx. kg

78

81

100

78

81

100

83
85

–

105
107
126

106
108
127

Battery capacity min / max 12 V - 45 / 88 Ah • 24 V - 36 / 55 Ah

Model S: non-encapsulated, normal system of balancing

Z: non-encapsulated, add. system of balancing
C: SILENT PACK, add. system of balancing

3.2. Transport

A lug is provided on top of the engine

as standard equipment, so that the en­gine can be lifted safely. It is not suitable for
lifting complete machines or similar with the
engine attached, and this is strictly prohibited.
(See Chapter 2.)

3.3. Instructions for installation

The „Manual for Selection and Installation of En­gines“ contains all the information you need if
your engine has not yet been installed on or in
the equipment it is intended to drive, or set up
in its correct operating position. You can obtain
a copy of this manual from your nearest HATZ
service station.
Moreover, we would like to point out that in this
case, commissioning is prohibited until it has
been verified that the machine into which this
engine is to be incorporated complies with the
regulations of the EC Machinery Directive.
Refer also to Chapter 9 „Declaration for Incorpo­ration“.

3

The permitted loads and elements on

the speed adjusting lever and the stop
lever should be observed as an exess can lead
to damage to the contacts and inner governor
parts.

3.4. Load on engine

Operating the engine for a lengthy period off­load or at very low loads can affect its running
quality.
We therefore recommend a minimum engine
load of 15 %. If operated at such low loads, it is
best to operate the engine at a significantly high­er load for a short period before switching it off.

3.5. Type plate

4

The type plate is placed on the crankcase resp.
on the capsule (chapt. 2) and includes the fol­lowing engine information:

➀ engine type
➁ code (only for special equipment)
➂ engine number
➃ max. engine speed

For any offer as well as spare parts orders it is
necessary to mention these data (also see spare
parts list, page 1).

➀

➁

➂

➃

70°

F 120 N

M 12.6 Nm

–

–

F 10 N

M 0.35 Nm

–

–

<

<

<

<

START

STOP

+

8

4. Operation

4.1. Before initial start-up

Engines are normally delivered without fuel and
oil.

4.1.1. Engine oil

Qualified are all trademark oils which fulfil at
least one of the following specifications:

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

significant.

If engine oil of a poorer quality is used, reduce
oil change intervals to 150 hours of operation.

Oil viscosity

5

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

Inappropriate engine oil may shorten the
engine’s service life significantly.

The engine must be in a horizontal position be­fore adding oil or checking the oil level.

6

– Pull out dipstick „1“ and add engine oil of the

correct specification and viscosity up to the

„max“ mark on the dipstick; (Chapter 3.1.).

4.1.2. Oil bath air cleaner

7

– Take off the oil reservoir and fill it up to the

mark „1“ using engine oil.

– Attach the oil reservoir, making sure that seal-

ing ring „2“ is correctly seated and catches „3“
are tight.

2393 / 6

2

3

1

1

-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

10W/40

10W/30

15W/40

30

40

122

10 W

9

4.1.3. Fuel

Only refuel when engine is stopped.

Never refuel close to open flames or
flammable sparks, don’t smoke. Use only pure
fuel and clean replenishing cups. Don’t spill
the fuel.

All diesel fuels sold as fuel and complying with
the following minimum specification can be
used:

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

Important !
The use of fuels of different specifications re­quires 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
diesel.
The fuel system is bled automatically if the
fuel tank is attached to the engine or located
higher than the injection pump.

9

– If the fuel tank is not mounted on top of the

engine, or is at a lower level, operate the lever
on the fuel feed pump until fuel is heard to
flow back to the tank through the return line.

10

– On fully encapsulated engines, move sleeve

„1“ to one side to gain access to the feed
pump.
After operating the feed pump, make sure that
the sleeve is replaced correctly and makes a
good seal.

1

2292 / 4

2287 / 11

2286 / 2

10

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

4.1.4. Mechanical oil pressure

monitor

(optional extra)

The mechanical oil pressure monitor should be
activated:

• when first filling, or after running the fuel tank

dry.

• if engine shut down automatically because lu-

bricating oil supply was inadequate.

• after freeing it by turning at low temperatures

(Chapter 4.2.4.)

• after replacing the fuel filter, Chapter 5.4.1.

– Add fuel, chap. 4.1.3.

– Check engine oil level, chap. 5.2.1.

11

– To activate the monitor, press lever „1“ for

approx. 15 seconds.

12

– If the engine has a full capsule, press pin „1“

for app. 15 seconds.

– If the engine has a fuel feed pump, operate its

lever for several strokes at the same time
(Figs. 9 and 10).

– Re-assemble all parts repositioned or re-

moved. Check that capsule elements make a
good seal.

2392 / 12

1

1

Lowest ambient

temperature when

starting, in °C

Paraffin content for:

Summer Winter

fuel fuel

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

11