HATZ Diesel 1D90W User Manual

0000 433 202 74 - ENG - 01.11 - 0.03

Printed in Germany

1D 90 V
1D 90 W

33

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.

We reserve the right to make modifications in the course of technical progress.

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 6

3.1. Technical data 6

3.2. Transport 7

3.3 Instructions for installation 7

3.4. Load on engine 7

3.5. Type plate 8

4. Operation 8

4.1. Before initial start-up 8

4.1.1. Engine oil 8

4.1.2. Fuel 9

4.1.3. Mechanical oil pressure monitor 10

4.2. Starting the engine 11

4.2.1. Preparations for starting 11

4.2.2. Electric starter 12

4.3. Stopping the engine 14

5. Maintenance 15

5.1. Maintenace summary 15

5.2. Maintenance every 8 – 15
hours of operation 17

5.2.1. Check engine oil level 17

5.2.2. Check air intake point 17

5.2.3. Air cleaner blockage indicator 17

5.2.4. Checking cooling air zone 18

5.2.5. Checking the water trap 18

Page

5.3. Maintenance every 250

hours of operation 19

5.3.1. Changing engine oil, renewing oil filter 19

5.3.2. Checking and adjusting
valve clearances 20

5.3.3. Clean the cooling air system 21

5.3.4. Checking threaded connections 21

5.4. Maintenance every 500
hours of operation 22

5.4.1. Renewing fuel filter 22

5.4.2. Dry-type air cleaner maintenance 22

6. Malfunctions – Causes – Remedies 24

7. Work on the electrical system 28

8. Protective treatment 28

Declaration for Incorporation 29

2

Contents

This symbol identifies important safety precautions.
Please comply with these most carefully in order to avoid any risk of injury to persons or
damage to materials.
General legal requirements and safety regulations issued by the competent authorities or
industrial accident insurers must also be complied with.

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.

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

strength.

– 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 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 maintenance in accordance with the details given in these operating instructions is essential
to keep the engine in good working order.

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

5

2. Description of engine

1

1 Oil filler pipe
2 Dipstick
3 Type plate
4 Combustion air intake
5 Dry-type air cleaner
6 Tank drain plug
7 Cylinder head cover
8 Tank filler cap
9 Cooling air inlet

10 Air cleaner maintenance indicator
11 Speed control lever
12 Oil filter (optional extra)
13 Fuel filter
14 Cooling air outlet
15 Silencer (muffler)
16 Starter motor
17 Central plug for electical system
18 Oil drain plug

6

3. General information

3.1. Technical data

Type 1D90.

Engine models V / W

Mode of operation air-cooled four-stroke diesel engine

Combustion method Direct-fuel injection

Number of cylinders 1

Bore / stroke mm 104 / 85

Displacement cm³ 722

Engine oil content without filter approx. L 1.5

1)

with filter approx. L 1.6

1)

Volume of oil between
„max“ and „min“ marks approx. L 0.7

1)

Consumption of lubrication oil
after running-in period approx. 1 % of fuel consumption at full load

Engine oil pressure
Oil temperature 100 ± 20 °C min. 0.6 bar at 850 r.p.m.

Direction of rotation
looking at the flywheel counterclockwise

Valve clearances at 10 - 30 °C
Inlet mm 0.30
Exhaust mm 0.30

Max. angle from vertical in any
direction (continuous operation) max. 25°

2)

Weight (incl. fuel tank, air-cleaner,
exhaust silencer and electric starter)
Engine models V approx. kg 106
Engine models W approx. kg 108

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

Model V: normal system of balancing, counterclockwise rotation

W: add. system of balancing, counterclockwise rotation

1)

These data are approx.-values. The max. mark on oil dipstick counts, fig. 6.

2)

Exceeding these limits causes engine breakdown.

3.2. Transport

2

Location for suspension lugs „1“,

please see picture 2.
Suspension lugs serve for save engine trans­port. They are not suitable and allowed for
lifting complete machines.

3.3. Instructions for installation

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 instal­lation. These Assembly Instructions contain im­portant information about safe assembly of the
engine and are available from your the HATZ
service center in your area.

Pending complete installation, the engine
must not be started !

Moreover, we would like to point out that in this
case, commissioning of the machine is also pro­hibited until it has been verified that the machine
into which this engine is to be incorporated
complies with all the safety precautions and reg­ulations provided by law.
Refer also to the Declaration for Incorporation
at the end of these Operating Instructions.

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.

7

3.5. Type plate

4

The type plate is placed on the crankcase
(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).

4. Operation

4.1. Before initial start-up

Engines are normally delivered without fuel and
oil.

4.1.1. Engine oil

Oil quality

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.

-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

➀

➁

➂

➃

8

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

6

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

– Add engine oil up to the max. mark on the

dipstick.
Lubricating oil capacity: see Chapter 3.1.

– Tighten oil fill screw by hand.

Attention !

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

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.

7

– Add diesel fuel to the fuel tank until it is at

leasthalf full.
The fuel system is bled automatically if the fuel
tank is attached to the engine or located higher
than the injection pump.

9

8

– 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.

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

4.1.3. 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

lubricating oil supply was inadequate.

– Add fuel, chap. 4.1.2.

– Check engine oil level, chap. 5.2.1.

9

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

approx. 15 seconds.

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

lever for several strokes at the same time
(Fig. 8).

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 %

10

10

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.

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.

11

Never use any spray starting aids.

4.2.1. Preparations for starting

– If possible, disengage the engine from any

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

0000 051 268 02

1 3 4

5

6

2

7

15s

11

12

– 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.

4.2.2. Electric starter

For preparations to start, see Chapter 4.2.1.

Starting procedure

13

– Insert start key and turn to position I (Fig. 13)

– Battery charge telltale „2“ and oil pressure

warning „3“ must light up.

– Turn start key to position II (Fig. 13).

– 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, chapter 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.

Note:

Start for max. 30 seconds. If the engine does
not run after this time, turn starter key back to

position 0 and eliminate the cause, Chapter 6.

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 starter protection module is installed, the
start key has to be returned to position 0 for at
least 8 seconds after the engine has failed to
start or after switching it off before a further at­tempt can be made to start the engine.

1

2

3

4

5

12

Preheating device with automatic heating
timer (additional equipment)

The preheating light „5“ lights up additionally at
temperatures below 0° Celsius (Fig. 13).

– After the light has gone out, start the engine

without delay.

Automatic shut-down function

(additional equipment)

This is characterized by a brief flashing of all
pilot lamps once the starter key has been turned
to position I (Fig. 13).

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. 13, 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.).

13

4.3. Stopping the engine

During breaks in work or at the con-

clusion of the working period, keep
the starting key in a safe place, out of reach
of unauthorized persons.

14

– Move speed control lever „1“ back to the STOP

position.

– On engines with the lower engine speeds not

accessible, move speed control lever „1“ back,
then move stop lever „2“ (optional extra) 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.

15

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 shut-down function
(chapter 4.2.2.), can also be switched off by
turning the start key back to position 0.

1

2

3

4

5

14

15

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 out of reach of unauthorized persons.
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.

5.2.1.

5.2.2.

5.2.3.

5.2.4.

5.2.5.

Every 250 operating
hours

Replace engine oil and oil filter.
Check and adjust tappet clearance.
Clean cooling air system.
Examine screw connections.

5.3.1.

5.3.2.

5.3.3.

5.3.4.

Every 500 operating
hours

Replace fuel filter.
Maintenance of dry-air filter.

5.4.1.

5.4.2.

8-15

500

250

16

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. 5.3.1.

– Check tappet clearance, and adjust if neces-

sary, chap. 5.3.2.

– Examine screw connections, chap. 5.3.4.

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.

16

IN

EX

= 1h

1D41:
1D42:
1D50:
1D81:
1D90:

IN 0.1 mm
IN 0.1 mm
IN 0.1 mm
IN 0.1 mm
IN 0.3 mm

/
/
/
/
/

EX 0.2 mm
EX 0.2 mm
EX 0.2 mm
EX 0.2 mm
EX 0.3 mm

0000 040 483 05

1D..

500h

250h

max

OIL

max

DIESEL

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.

17

– For oil level inspection, remove the dipstick

and wipe it dry using a lint-free, clean piece of
cloth; then insert it to its stop and pull it out
again.

– Check oil level at the dipstick; top up if

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

Attention !

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.

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).

5.2.3. Air cleaner blockage indicator

(optional extra)

– Run the engine at full speed shortly.

18

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.

m

ax

.

m

in

.

17

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 5.3.3.).
If a temperature warning light „4“ is provided,
it will come on if the engine overheats
(Fig. 15).

In this case, stop the engine immediately

(Chapters 4.3. and 5.3.3.).

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.

19

– 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.

20

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

into a suitable vessel.

If the drain plug is difficult to reach, an exten­sion hose can be attached to it.

18

5.3. Maintenance every 250

hours of operation

5.3.1. 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.

Danger of scalding from hot oil.

Trap the old oil and dispose of it in

accordance with local legislation.

21

– Unscrew the oil drain plug „1“ and allow all the

oil to drain out.

– Clean the oil drain plug and attach a new

seal „2“. Insert and tighten the plug.

22

– Renew the replaceable lubricating oil filter-

element (optional extra). Catch leaking oil !

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

23

– 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 to animals, persons or yourself !

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

necessary (Fig. 22).

19

– Wet the thread and the O-ring of the drain 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.

5.3.2. Checking and adjusting

valve clearances

24

– Unscrew cover „1“ and take off together with

gasket „2“. Never re-use this gasket.

– Turn the engine over in the normal direction of

rotation until compression is felt.

25

– Check valve clearances between rocker and

valve stem, using feeler gauge „1“; (see
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.

– Run the engine briefly and check that the

cover is not leaking.

20

5.3.3. 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 !

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.

– 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.

5.3.4. 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.

26

Adjustment screws on speed governor
and injection system are painted with

safty lacquer. Do not tighten or adjust them.

21

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.

– Place a suitable vessel under the filter to trap

escaping fuel.

– Close the fuel supply line.

27

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

both sides, and insert the new filter.

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

– Always renew the fuel filter. Note the arrows

indicating the correct direction of fuel flow.

– Open the fuel supply line or prime the pump

until the fuel flows (see Chapter 4.1.2.).

– 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.

28

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

cover „2“.

22

29

– 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.

Cleaning the filter cartridge

Dry contamination

30

– 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. 29)

Wet or oily contamination

– Renew the filter cartridge.

– Re-assemble in the reverse order of work.

23

24

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

- Valves worn

- 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.

See workshop manual.

Check engine oil level.

Activate mechanical oil pressure
monitor.

Operate preheat system
(optional extra).

Disengage engine from machin­ery or equipment if possible.

See workshop manual.

4.2.

4.1.2.

4.1.3.

5.4.1.

4.1.2.

5.3.2.

5.2.1.

4.1.3.

4.2.2.

25

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.

4.1.2.

5.3.1.

7.

7.

5.4.1.

5.2.1.

5.3.3.

26

Malfunction Possible causes Remedial action Chap.

Engine stops by
itself during re­gular operation.

In addition, if auto­matic electrical en­gine shutdown is
installed.

Low engine power,
output and speed.

Fuel supply is interrupted:

- Tank run dry

- Fuel filter blocked

- Defective feed pump.

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.

Fuel supply is obstructed:

- Tank run dry.

- Fuel filter blocked.

- Tank venting is inadequate

- Leaks at pipe unions.

- Speed control lever does not
remain in selected position.

Add fuel.

Renew fuel filter.
Check through entire fuel supply
system.
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.

Add fuel.

Renew fuel filter.
Ensure that tank is adequately
vented.
Check threaded pipe unions for
leaks.
Prevent speed control from
moving.

4.1.2.

4.1.3.

5.4.1.

5.2.1.

4.1.3.

5.2.1.

5.3.3.

4.1.2.

4.1.3.

5.4.1.

27

Malfunction Possible causes Remedial action Chap.

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

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

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.

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.

5.4.2.

5.3.2.

5.3.1.

5.3.3.

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.

– 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.

28

29

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.