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

13

Instructions to activate the mechanical oil pres­sure control are mentioned on the sticker placed
on the engine.

IMPORTANT !
Even with mechanical oil pressure monitoring
the oil level must be checked every 8 – 15
operating hours (Chapter 5.2.1.).

4.2. Starting the engine

Do not run the engine in closed or

badly ventilated rooms – danger of
poisoning ! Before the engine is started, al­ways make sure that nobody is in the danger
area (moving parts on engine or machinery)
and that all safety guards are in place.

Check that the starting handle is in good condi­tion: renew tubular grip if broken, worn drive pin
etc.
Lightly grease the sliding-contact area between
the starting handle and the guide sleeve.

14

Do not enter the guide sleeve of
the starting device whilst engine
is running - risk of injury !

15

Never use any spray starting aids.

050 145 00

L3 / 250

0000 053 755 00

15s

0000 051 268 02

1 3 4

5

6

2

7

12

4.2.1. Preparations for starting

– If possible, disengage the engine from any

driven equipment. The auxiliary equipment
should always be placed in neutral.

16

– Set speed control lever „1“ to a position be-

tween 1/2 START and max. START, according
to requirements. Selecting a lower engine
speed will reduce smoke when starting.

– Make sure that stop lever „2“ - if fitted - is in

the operating „START“ position.

17

18

– Turn the decompression lever until stop „1“ is

reached. In this position the automatic decom­pression system is heard to engage and the
engine can then be started; Figs. 17 and 18.

19

After the automatic decompression device has
engaged at its limit stop, five turns of the crank
handle are needed for the engine to build up
compression and fire again.

2

2

3

5x

1

1

0

2292 / 6

1

0

2283 / 4

2396 / 3

2

1

START

START

STOP

STOP

13

4.2.2. Starting with the handle

For preparations to start the engine,
see Chapter 4.2.1.

20

For correct position to adopt when starting the
engine, see Fig. 20.

Starting with the handle with kick-back
damping (retrofit)

21

– Always hold tubular grip „1“ with both hands.

– Turn the handle slowly until the pawl engages

in the ratchet, then increase turning force to
build up speed. The highest speed must have
been reached when the decompression lever
returns to the „0“ position (compression). As
soon as the engine has started, pull the start­ing handle out of the guide sleeve.

You must hold the tubular grip firmly to

maintain contact all the time between
the starting handle and the engine. Maintain
turning force during the entire hand starting
operation.

If backfiring occurs when starting the engine be­cause the crank handle was not turned firmly
enough, the brief reverse rotation at the handle
tube separates the link between crank lug „2“
and driving dog „3“ (Fig. 21).

– If the engine begins to run backwards after

backfiring (smoke emerges from air cleaner),
release the crank handle immediately and stop
the engine (Chapter 4.3.).

– To restart the engine, wait until it has come to

a standstill, then repeat the starting prepara­tions.

Starting by means of the standard
starting crank

In the countries of the European Union,

starting cranks without kick-back dam-

ping must not be used.

For preparations to start the engine,
see Chapter 4.2.1.

– For correct position to adopt when starting the

engine, see Fig. 20.

3

2 1

2395 / 4

14

– Take hold of the starting handle with both

hands and turn it at increasing speed. The
maximum speed of rotation must have been
reached by the time the decompression lever
has returned to the „0“ position (compres­sion). As soon as the engine has started, pull
the starting handle out of the guide sleeve.

– If the engine backfires because the crank han-

dle was not turned firmly enough (the engine
may even start to run backwards), release the
crank handle immediately and stop the engine
(Chapter 4.3.).

There is a risk of injury from the
rotating crank handle.

– To restart the engine, wait until it has come to

a standstill, then repeat the starting prepara­tions.

Safety precaution

For greater protection against accidental injury
when starting with the handle, a handle with
kick-back damping can be used.

4.2.3. Starting in cold weather

At temperatures below app. –5 °C, always turn
the engine over to ensure that it rotates freely.

– Move the speed control lever to the START

position; Fig. 16.

– Place decompression lever in central position

between „0“ and „1“ (Fig. 17 and 18).

– Turn the engine over with the starting handle

until it is felt to rotate more freely (10 – 20
turns of the starting handle).

– If mechanical oil pressure monitoring is

fitted, press lever „1“ or pin „1“ in for about
15 seconds (Figs. 11 and 12).

22

23

– Remove dirt from the cover of the metering

device and the surrounding area. Pull off the
cover; Figs. 22 and 23.

– Add a free-flowing lubricating oil to the

housing until the level reaches the upper rim.
Replace the cover and press it in firmly. Two
filling operations in succession are needed.

– Turn the decompression lever until

limit stop „1“ (fig. 17 and 18).

– After this, start the engine immediately.

Chap. 4.2.1. / 4.2.2.

2392 / 9

2283 / 8

15

4.2.4. Electric starter

For preparations to start, see Chapter 4.2.1.

– The decompression lever remains in pos. „0“.

Starting procedure

24

– Insert the key to its stop and turn it to

position I.

– Battery charge telltale „2“ and oil pressure

warning „3“ must light up.

– Turn start key to position II (fig. 24).

– As soon as the engine runs, release the start

key. It must return to position I by itself and
remain in this position during operation.
The battery charge telltale and oil pressure
warning must go out immediately after start­ing. Indicator light „1“ is on when the engine
is in operation.

– If anything seems to be incorrect, stop the en-

gine immediately and trace and rectify the fault
(chapt. 6).

– The engine temperature display „4“ (additional

equipment) lights up if the temperature at the
cylinder head becomes too high.

Switch off the engine and trace and elimi­nate the cause of the problem, chap. 6.

– Always turn the start key back to position 0

before re-starting the engine. The repeat lock
in the ignition lock prevents the starter motor
from engaging and possibly being damaged
while the engine is still running.

Never operate the electric starter when

the engine is running or coasting to a
standstill. There is a risk of broken starter pin­ion or ring gear teeth.

Important:

If a start protection module is installed, the start
key has to be returned to position 0 for at least
8 seconds if the engine has failed to start before
a further attempt to start the engine can be
made.

Preheating device with automatic
heating timer

(additional equipment)

The preheating light „5“ lights up additionally at
temperatures below 0° Celsius (Fig. 24).

– After the light has gone out, start the engine

without delay.

1

2

3

4

5

16

Automatic electrical shutdown system

(additional equipment)

This is characterized by a brief flashing of all
pilot lamps once the starter key has been turned
to position I (Fig. 24).

Important !

If the engine cuts out immediately after starting
or switches off by itself during operation, a
monitoring element in the automatic shutdown
system has tripped. The corresponding indicator
light (Fig. 24, positions 2 - 4) will come on.
After the engine has stopped, the display con­tinues to glow for about 2 minutes.
The electrical device then switches itself off au­tomatically.
The display lights up again after the start key
has been turned back to position 0 and then to

position I again.
Trace and eliminate the cause of the operating
fault before trying to restart the engine

(see chapter 6).

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

Even with automatic shutdown monitoring the
oil level must be checked every 8 – 15 operat­ing hours (Chapter 5.2.1.).

4.3. Stopping the engine

Never stop the engine by moving the

decompression lever. During breaks
in work or at the conclusion of the working pe­riod, keep the starting handle and starting key
in a safe place, out of reach of unauthorized
persons.

25

Never stop the engine by actuating the

decompression lever !

Risk of damage to the engine.

26

– Move speed control lever „1“ back to the

STOP position.

2396 / 3

2

1

START

START

STOP

STOP

0000 050 616 01

17

– On engines with the lower engine speeds

not accessible, move speed control lever „1“
back, then move stop lever „2“ in the STOP
direction. Hold it there until the engine has
stopped.

– Once the engine is not running any longer,

release the stop lever.
The stop lever is returned automatically to its
operating position START via a spring.

Electrical system

27

The charge „2“ and oil pressure telltales „3“
come on.

– Turn the key to the 0 position and pull it out.

The telltale lights must then go out.

Note:
Engines with an automatic electrical shutdown
system (Chapter. 4.2.4.) can also be switched
off by turning the start key back to position 0.

1

2

3

4

5

18

19

5. Maintenance

The engine must be stopped before any maintenance work is attempted.

Comply with legal requirements when handling and disposing of old oil, filters and
cleaning materials.
Keep the engine’s starting key and starting handle out of reach of unauthorized persons.
To immobilize engines with an electric starter, disconnect the negative battery terminal.
At the end of the maintenance work, check that all tools have been removed from the engine and
all safety guards, covers etc. replaced in their correct positions.
Before starting the engine, make sure that nobody is in the danger area (engine or driven
machinery).

5.1. Maintenance summary

Maintenace intervals Maintenance work required Chap.

Every 8 – 15 operating
hours or before daily
starting.

Check oil level.
Check area round combustion air input.
Check the air cleaner maintenance indicator.
Check the cooling air zone.
Check the water trap.
Check the lower part of the oilbath air cleaner for
correct oil level and freedom from dirt; renew oil if
sludge has formed.

5.2.1.

5.2.2.

5.2.3.

5.2.4.

5.2.5.

4.1.2.

5.3.1.

Every 250 operating
hours

Maintenance of oil bath air filter.
Replace engine oil and oil filter.
Check and adjust tappet clearance.
Clean cooling air system.
Examine screw connections.
Cleaning mesh insert in exhaust silencer

5.3.1.

5.3.2.

5.3.3.

5.3.4.

5.3.5.

5.3.6.

Every 500 operating­hours

Replace fuel filter.
Maintenance of dry-air filter.

5.4.1.

5.4.2

8-15

500

250

28

The above maintenance chart is supplied with
every engine. This label should be affixed to the
engine or equipment in an easily visible position.
The maintenance chart governs the maintenance
intervals.

For new or reconditioned engines, the following
must always be carried out after first 25 operat-

ing hours:

– Replace engine oil and oil filter, chap. 5.3.2.

– Check tappet clearance, and adjust if neces-

sary, chap. 5.3.3.

– Examine screw connections, chap. 5.3.5.

Do not tighten the cylinder head fastening.

For short operating periods: replace engine oil

and oil filter after 12 months at the latest, re­gardless of the number of operating hours.

20

21

5.2. Maintenance every 8 – 15

hours of operation

5.2.1. Check engine oil level

When checking the oil level, the engine should
be standing level, and must not be running.

– Remove any dirt in the dipstick area.

29

– Check oil level at the dipstick; top up if neces-

sary as far as the „max“ mark
(see Chapter 4.1.1.).

5.2.2. Check air intake point

Severe contamination is a sign that there are
large amounts of dust in the atmosphere and
the air cleaner maintenance intervals should be
reduced.

– Depending on the air intake pattern, check for

severe blockage; clean if necessary
(see Chapter 2).

30

– Check that dust outlet „1“ on the centrifugal

dust trap (depending on version) is not
blocked, and clean if necessary.

5.2.3. Air cleaner blockage indicator

(optional extra)

– Run the engine at full speed shortly.

31

If the rubber bellows is pulled in and obscures
the green zone „1“, maintenance work is due on
the air cleaner; Chapt. 5.4.2. In dusty operating
conditions, check the rubber bellows several
times a day.

2391 / 10

1

2393 / 10

1

5.2.4. Checking cooling air zone

Severe contamination is a sign that there are
large amounts of dust in the atmosphere and
that maintenance intervals should be reduced.

– Check the air inlet and outlet zones for block-

age by coarse material such as leaves, large
amounts of dust etc., and clean if necessary
(see chapters 2 and 5.3.4.).

– If a temperature warning light „4“ is provided,

it will come on if the engine overheats, fig. 27.

In this case, stop the engine immediately

(Chapter 4.3. and 5.3.4.).

5.2.5. Checking the water trap

The intervals at which you should check the
water trap depend entirely on the amount of
water in the fuel and the care taken when re­fuelling. The normal interval is once a week.

32

– Loosen hexagon screw „1“ with approx. 2-3

rotations.

– Trap the drops which emerge in a transparent

vessel. Since water has a greater specific
gravity than diesel fuel, the water emerges be­fore the diesel fuel. The two substances sepa­rate at a clearly visible line.

– As soon as diesel only emerges at screw „1“,

this can be tightened again.

If an external water trap is attached, check its
water content every day, when the engine oil
level is checked. The water which has collected
is separated at a clearly visible line from the
diesel fuel above it.

33

– Open drain plug „1“ and drain the water out

into a suitable vessel.

– If the drain plug is difficult to reach, an exten-

sion hose can be attached to it.

2396 / 9

1

2396 / 7

1

22

5.3. Maintenance every 250

hours of operation

5.3.1. Oil bath air cleaner maintenance

34

Catch waste oil and dispase acc. to

environmental regulations.

– Take off the oil reservoir „1“ and clean it.

– Remove contaminated oil and sludge from the

oil tank, and clean it out.

– Take off rain cap „2“ and clean it.

– Clean the entire length of intake pipe „3“.

– Check the inserted seal and renew if in poor

condition.

– Fill the oil reservoir up to the mark with engine

oil and re-assemble the oilbath air cleaner,
Chap. 4.1.2.

– If the filter pack is very dirty, also clean the

upper part of the air cleaner as follows:
Remove the upper part of the air cleaner from
the engine and rinse it in diesel oil.

– Before re-assembling the air cleaner, allow the

diesel fuel to drip off thoroughly, or wipe it off.

– Never attempt any repairs (welding, brazing

etc.) to the oilbath air cleaner, or it may be
rendered useless and the engine may also be
damaged.

– If the sealing face is uneven, the air cleaner

body cracked and/or the filter wool content is
incomplete, install a new air cleaner.

– Attach the upper part of the air cleaner with a

new flange gasket.

35

– Sealing package acc. picture 35 is mounted at

engines 1D41, 1D42 and 1D50.

36

– Shim washers „1“ should be installed with the

convex side (outward curve) towards the nut.

– Re-assemble the complete air cleaner and fill it

with oil to make it ready for further operation.

1

2395 / 13

23

5.3.2. Changing engine oil,

renewing oil filter

The engine must be stopped, and should stand
on a flat, level surface.
Drain the engine oil only when it is warm.
For oil drain plug, see Chapter 2.

Risk of scalding from hot oil.

Catch waste oil and dispase acc. to

environmental regulations.

37

– Unscrew the oil drain plug and allow all the oil

to drain out.

Fully encapsulated engines:

38

When unscrewing oil drain plug „1“, make sure
that the drain tube is not loosened. Prevent it
from turning if necessary with an open-ended
wrench of the correct size.

– Clean the oil drain plug and attach a new seal.

Insert and tighten the plug.

39

– Renew the replaceable lubricating oil filter ele-

ment.

1

2287 / 13

2292 / 9

1

24

40

– Clean sieve bottom carefully in order not to

bend the netting.
Wipe out cap screw or blow it out with com­pressed air.

Persons handling compressed air must

wear protective goggles. Never direct

the jet at animals, persons or yourself !

Important !
Note the „TOP“ mark on the oil filter. Fig. 39

– Check condition of O-ring „1“ and renew it if

necessary (Fig. 39).

– Wet the thread and the O-ring of the screw

plug with lubricant „K“ (see spare parts list).

– Add engine oil up to the „MAX“ mark on the

dipstick (see Chapter 4.1.1.)

– Run the engine for a short period, then check

the oil level again and top up if necessary.

– Check that there is no leakage past screw plug

on the oil filter housing.

5.3.3. Checking and adjusting
valve clearances

– Move the decompression lever to

position „0“; Fig. 17 and 18.

41

– In case of the enclosed design, please remove

the parts of the enclosure in the order 1...4.
The decompression lever is also taken off
when the cover is removed.

42

– Unscrew cover „1“ and take off together with

gasket „2“. Never re-use this gasket.

2393 / 15

0

1

2

1

2

3

4

25

– Turn the engine over in the normal direction of

rotation until compression is felt.

43

– Check valve clearances between rocker and

valve stem, using feeler gauge „1“. For the
setting, refer to Chapter 3.1.

– If valve clearance is incorrect, slacken off hex.

nut „2“.

– Turn adjusting screw „3“ with a screwdriver

until feeler gauge „1” can just be pulled
through between the rocker and the valve
stem with slight resistance to its movement
after nut „2“ has been retightened.

– Attach the cover at the cylinder head again and

tighten down uniformly.

– Depending on version mount parts of air duct.

44

– In case of the enclosed design, place the lever

for decompression „1“ in horizontal position.
Then, mount the cover of the enclosure in the
order 2...3.

– After a short test run, check the cylinder head

cover for leakage.

5.3.4. Clean the cooling air system

Before cleaning, the engine must be
stopped and allowed to cool down.

Remove parts of air duct.

Dry contamination

– Clean all air guide elements and the complete

cooling air zones on the cylinder head, cylin­der and flywheel blades without making them
wet. Blow them dry with compressed air.

Persons handling compressed air must
wear protective goggles. Never direct
the jet to animals, persons or yourself !

1

2

3

1

3

2

26

Moist or oily contamination

– Disconnect the battery. Clean the complete

area with a solvent, cold cleaner etc. according
to its manufacturer’s instructions, then spray
down with a powerful water jet.
Do not splash electrical device with water jet
or pressure jet during engine cleaning.

Important !
When cleaning the engine, do not direct a
jet of water or a high-pressure jet at the
components of the electrical equipment.

– Trace the cause of any contamination with oil

and have the leak eliminated by a HATZ
service station.

– Install the air guide elements previously re-

moved.

The engine must never be run without
the air guide elements in position.

– Immediately after re-assembly, run the engine

until warm to prevent residual moisture from
causing rust.

5.3.5. Checking threaded connections

Check the condition and tightness of all threaded
connections, wiring, hose clips and other com­ponents attached to the engine and its mount­ings, provided that these can be reached during
maintenance work.

Do not tighten the cylinder head bolts.

45

Adjustment screws on speed governor
and injection system are painted with

safty lacquer. Do not tighten or adjust them.

5.3.6. Cleaning mesh insert in exhaust
silencer

(additional equipment)

46

– Remove deposits from the mesh insert with a

suitable wire brush.

2396 / 3

27

5.4. Maintenance every 500

hours of operation

5.4.1. Renewing fuel filter

Fuel filter maintenance intervals depend on the
purity of the fuel used; reduce them to 250
hours of operation if necessary.

Do not smoke or bring a naked flame
near the fuel system when working
on it.

Important !
Keep the entire area clean so that no dirt
reaches the fuel. Fuel particles may damage
the injection system.

47

– Shut off the fuel supply line upstream and

downstream of the fuel filter according to
item 1.

48

– Unscrew the fuel filter from its mount.

49

– Place a suitable vessel under the filter to trap

escaping fuel.

– Pull off fuel supply line „1“ at both ends of fuel

filter „2“ and insert the new filter.

– Always renew the fuel filter. Note the arrows

indicating the correct direction of fuel flow.

– Secure the filter to its mount.

– Open the fuel supply line or prime the pump

until the fuel flows (see Chapter 4.1.3.).

1

2

1

28

– Activate mechanical oil pressure monitor

(optional extra), chap. 4.1.4.

– Run the engine briefly to check the fuel filter

and lines for leaks.

5.4.2. Dry-type air cleaner maintenance

It is best to clean the filter cartridge only when
the maintenance indicator displays the appropri­ate signal.
Apart from this, the cartridge should be renewed
after 500 hours of operation.

50

– In case of the enclosed design, please remove

the cover of the enclosure in the order 1...2.
The decompression lever is also taken off
when the cover is removed.

51

– Slacken off wing bolt „1“ and remove it with

cover „2“.

52

– Carefully pull out filter cartridge „1“.

– On the version with air cleaner maintenance

indicator, check that valve plate „4“ is clean
and in good condition.

– Clean filter housing and cover.

Make sure that dirt or other foreign matter
cannot enter the engine air intake port.

2393 / 1

42

1

2396 / 16

1

2

1

2

29

Cleaning the filter cartridge

Dry contamination

53

– Blow through the filter cartridge from the in-

side, moving the jet of dry compressed air up
and down until no further dust is expelled.

Warning: air pressure must not exceed 5 bar.

Persons handling compressed air must
wear protective goggles. Never direct
the jet to animals, persons or yourself !

– Tilt the filter element and hold it against the

light (or shine a light through it) to trace any
cracks or other damage.

Important:
If there is even the slightest damage to paper
filter element „2“ or sealing lips „3“, the filter
element should not be re-used. (Fig. 52)

Wet or oily contamination

– Renew the filter cartridge.

– Re-assemble in the reverse order of work.

54

– In case of the enclosed design, place the lever

for decompression „1“ in horizontal position.
Then, mount the cover of the enclosure in the
order 2...3.

1

2

3

2281 / 5

30

31

6. Malfunctions – Causes – Remedies

Malfunction Possible causes Remedial action Chap.

Engine will not
start or start is
delayed, although
it can be turned
over with the
starter.

Also applicable for
engines with me­chanical oil pres­sure monitoring.

At low tempera­tures.

Speed control lever is in stop or
idle position.
Stop lever in stop position.

No fuel reaching injection pump.

Compression too low:

- Valve clearances incorrect

- Cylinder bore and/or piston
ring wear

Injector not operating correctly.

Oil pressure lost.

Lower starting temperature limit
exceeded.

Machinery not uncoupled.

Defective preheat system
(optional extra).

Set lever to „START“-position

Add. fuel.

Check entire fuel supply system
carefully.
If no fault is found:

- supply line to engine

- fuel filter

- Function of delivery pump
must be checked.

Check valve clearances, adjust if
necessary.

See workshop manual.

See workshop manual.

Check engine oil level.

Activate mechanical oil pressure
monitor.

Comply with cold starting
instructions.
Operate preheat system
(optional extra).

Disengage engine from machin­ery or equipment if possible.

See workshop manual.

4.2.

4.1.3.

4.1.4.

5.4.1.

4.1.3.

5.3.3.

5.2.1.

4.1.4

4.2.3.

4.2.4.

32

Malfunction Possible causes Remedial action Chap.

At low
temperatures.

Starter does not
run or engine is
not turned over.

Engine fires but
stops again as
soon as starter is
switched off.

Fuel separates has inadequate
resistance to low temperatures.

Starting speed too low:

- Engine oil is too thick

- Battery charge is insufficient.

Fault in electrical system:

- Battery and/or other wiring is
wrongly connected.

- Wiring connections loose
and/or corroded.

- Battery defective and/or flat.

- Defective starter motor

- Defective relays, monitoring
elements etc.

Drive still engaged.

Fuel filter blocked.

Fuel supply interrupted.

Stop signal from monitoring
element for automatic shutdown
system (optional extra):

- oil pressure lost

- cylinder head temperature

too high.

- alternator has failed

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 supply system.
Refuel with winter-grade fuel to
which paraffin has been added.

Refill with a different grade of
engine oil.

Check the battery; consult a spe­cialist workshop if necessary.

Check electrical system incl.
indiv. components or contact a
HATZ-service station.

Uncouple engine from driven
machinery if possible.
Renew the fuel filter.

Check through the entire fuel
supply systematically.

Check oil level.

Clean cooling air system.

See workshop manual.

4.1.3.

5.3.2.

7.

7.

5.4.1.

5.2.1.

5.3.4.

33

Malfunction Possible causes Remedial action Chap.

Engine stops by
itself during re­gular operation.

In addition, if auto­matic engine shut­down is installed.

Fuel supply is interrupted:

- Tank run dry

- Fuel filter blocked

- Defective feed pump.

- Air in the fuel system.

Mechanical oil pressure monitor
stops the engine due to low oil
pressure.

Mechanical defects.

Stop signal from monitoring
element because of:

- oil pressure too low.

- cylinder head temperature
too high.

- alternator has failed

Malfunction signal from over-

voltage and polarity reversal
protection in voltage regulator:

- Battery and/or other cable
connections incorrectly con­nected.

- Cable connections loose.

Add fuel.

Renew fuel filter.
Check through entire fuel supply
system.
Check fuel system for
penetration of air.
Check air vent valve.

Check engine oil level.
Activate mechanical oil pressure
monitor.

Contact a HATZ-service station.

Check engine for:
Engine oil level.
Cooling air passages blocked
or cooling system otherwise
affected.
See workshop manual.

Check electrical equipment and
the components thereof.

4.1.3.

4.1.4.

5.4.1.

5.2.1.

4.1.4.

34

Malfunction Possible causes Remedial action Chap.

Low engine power,
output and speed.

Low engine power,
output and speed,
black exhaust
smoke.

Engine runs very
hot. Cylinder head
overheat, telltale
lamp (optional
extra) comes on.

Fuel supply is obstructed:

- Tank run dry.

- Fuel filter blocked.

- Tank venting is inadequate

- Leaks at pipe unions.

- Air in the fuel system.

- Speed control lever does not
remain in selected position.

Air cleaner blocked.

Incorrect valve clearances.
Malfunction at injector.

Too much oil in engine.

Inadequate cooling:

- Entire cooling air system
contaminated.

- Inadequate sealing at air guide
plates or capsule elements.

Add fuel.

Renew fuel filter.

Ensure that tank is adequately
vented.
Check threaded pipe unions for
leaks.
Check fuel system for
penetration of air.
Check air vent valve.

Prevent speed control from
moving.

Remove dirt from air cleaner.

Adjust valve clearances.
See workshop manual.

Drain off engine oil down to
upper mark on dipstick.

Clean cooling air system.

Check that air guide plates and
enclosure elements are all pres­ent and make a tight seal.

4.1.3.

4.1.4.

5.4.1.

5.3.1.

5.4.2.

5.3.3.

5.3.2.

5.3.4.

7. Work on the electrical system

Batteries generate explosive gases.

Keep them away from naked flame
and sparks which could cause them to ignite.
Do not smoke. Protect the eyes, skin and
clothing against battery acid. Pour clear water
over acid splashes immediately. In case of
emergency call doctor.
Do not place any tools on top of the battery.

Always disconnect the negative (–) pole of the
battery before working on the electric device.

– The positive (+) and negative (–) battery ter-

minals must not be accidentally interchanged.

– When installing the battery, connect the posi-

tive lead first, followed by the negative lead.
Negative pole to earth (ground) on engine
block.

– When removing the battery, disconnect the

negative lead first, followed by the positive
lead.

– In all circumstances, avoid short circuits and

shorts to earth (ground) at live cables.

– If electrical faults occur, first check for good

contact at the cable connections.

– Replace a failed indicator light without delay.

– Do not take the key out while the engine is

running.

– Never disconnect the battery while the engine

is running. Electric 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 engine.

– For emergency operation without battery,

make sure that the plug-and-socket connector
to the instrument box is disconnected addi­tionally before the engine is started.

– Do not splash electrical device with water jet

or pressure jet during engine cleaning.

– When carrying out welding work on the en-

gine or attached equipment, attach the earth
(ground) clip as near as possible to the weld­ing point, and disconnect the battery.
If an alternator is fitted, separate the plug con­nector leading to the voltage regulator.

The relevant circuit diagrams are supplied with
engines which have an electrical system.
Additional copies of circuit diagrams can be
obtained on request.

HATZ assumes no liability for electrical systems
which was not carried out acc. HATZ circuit dia­grams.

8. Protective treatment

A new engine can normally be stored for up to
12 months in a dry place.
If atmospheric humidity is high (or if exposed
to sea air), protection is sufficient for about
6 months’ storage.
If the engine is to be stored for a longer period,
or laid up out of use, please consult the nearest
HATZ service point.

35

36

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.