Winco 1B40 User Manual
INSTRUCTION BOOK
1B20
1B30
1B40
43380204-ENG-01.01-2.5
Printed in Germany
A new HATZ Diesel engine - working for you
This engine is intended only for the purpose determined 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 accepts no warranty. 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.
Please do not fail to read this operating manual before starting the engine. This will help you to avoid
accidents, ensure that you operate the engine correctly and assist you in complying with the maintenance intervals in order to ensure long-lasting, reliable performance.
Please pass this Instruction Manual on to the next user or to the following engine owner.
The worldwide HATZ Service Network is at your disposal to advise you, supply with spare parts and
undertake servicing work.
You will find the address of your nearest HATZ service station in the enclosed list.
Use only original spare parts from HATZ. Only these parts guarantee a perfect dimensional stability
and quality. The order numbers can be found in the enclosed spare parts list. Please note the spare
part kits shown in Table 1.
We reserve the right to make modifications in the course of technical progress.
MOTORENFABRIK HATZ GMBH & CO KG
1
Contents
Page
1. Important safety notes when operating the engine 3
2. Description of the engine 5
3. General notes 6
3.1. Technical data
3.2. Transport
3.3 Notes on installation
3.4. Load on engine
3.5. Type plate
4. Operation 7
4.1. Prior to first-time start-up
4.2. Starting
4.3. Switching off - Stopping
5. Maintenance 12
5.1. Maintenance chart
5.2. Maintenance every 8–15 operating hours
5.3. Maintenance every 250 operating hours
5.4. Maintenance every 500 operating hours
5.5. Maintenance every 1000 operating hours
6. Malfunctions–causes–remedies 19
7. Work on the electrical system 23
8. Storage out of use 23
9. Warranty 23
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.
2
1. Important safety notes when operating the engine
HATZ diesel engines are efficient, strong and durable. For this reason they are frequently installed on
equipment used for commercial purposes.
The manufacturers of such equipment must observe any relevant equipment safety regulations when
the engine forms part of an overall system.
A few general points concerning operating safety should none the less be noted.
Depending on the engine's operating and installation conditions, equipment manufacturers and their
users may have to fit safety or protective devices in order to prevent improper use. Examples:
– Exhaust system components as well as the surface of the engine will naturally be hot and must not
be touched while the engine is running or until it has cooled down after being stopped.
– Incorrect wiring or improper operation of the electrical system may cause sparking and must there-
fore be avoided.
– Provide protection against contact with rotating parts once the engine is connected to the driven
equipment or machine.
HATZ protective guards are available for the belt drive of the cooling fan and alternator drive systems.
– Always observe the start-up information in the operating instructions before starting the engine:
this is particularly important when starting an engine with the recoil starter.
– Mechanical starting devices should not be operated by children or persons deficient in physical
strength.
– Check that all safety devices are in place before starting the engine.
– Ensure that operation, maintenance and repair of the engine are undertaken by suitably trained per-
sonnel only.
– Protect the starter key against unauthorised use.
– Do not 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.
3
Important safety notes when operating the engine
– The engine must be stopped before performing any maintenance, cleaning- or repair work.
– Stop the engine before refilling the fuel tank.
Never refuel near a naked flame or sparks which could start a fire. 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 the engine while it is running.
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. Contact your next HATZ Servicestation, if a sticker comes off or is illegible and ask
for a new one.
– We accept no liability for damage resulting from improper modifications to the engine.
Regular maintenance in accordance with the details given in these operating instructions is essential
to keep the engine in good working order.
When in doubt, consult your local HATZ service station before starting the engine.
4
2. Description of the engine
5
Fig. 1
1 Type plate
2 Cylinder head cover
3 Exhaust silencer
4 Exhaust mesh insert
5 Oil pressure switch
6 Starter motor
7 Voltage regulator
8 Crankshaft - power take-off
9 Oil drain plug
10 Speed adjustment lever
11 Oil filter
12 Engine mountings
13 Ignition key
14 LED display
15 Intake opening for cooling and
combustion air
16 Oil filler pipe and dipstick
17 Recoil starter
18 Engine shutdown pin
19 Dry-type air cleaner
20 Lifting lug (see also Fig 32, Pos. 1)
21 Fuel tank cap
22 Noise insulating hood
12
3
4
5
6
7
8910
2122
9
11
12
20
13
19
18
17
16
15
14
3. General notes
3.1. Technical data
Type 1B20 1B30 1B40
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 1 1 1
Bore / stroke mm 69 / 62 80 / 69 88 / 76
Displacement cm
3
232 347 462
Lubricating oil capacity l, approx. 0.9* 1.1* 1.5*
Difference between
“max” and “min” levels l, approx. 0.5* 0.5* 0.8*
Lubricating oil consumption
(after running in) approx. 0.5 % of fuel consumption at full load
Lubricating oil pressure
(oil temperature 100 °C) approx. 2.5 bars at 3000 r.p.m.
Direction of rotation,
power take-off end anti-clockwise
Valve clearance 10 - 30 °C
Inlet and exhaust valve mm 0.10
Max. tilt angle in operation, Flywheel 25° down
in direction all other directions 35°
Weight (incl. fuel tank, air-cleaner,
exhaust silencer, recoil starter and kg,
electric starter) approx. 33 38 55
Battery capacity Amp/h max. 12 V / 60 Amp/h
* These values are intended as an approximate guide. The max. marking on the dipstick is the
determining factor, Fig. 7.
Tightening torques
Item Nm
Oil drain plug 50
6
3.2. Transport
Standard lifting lug „20“ is to allow
the engine and its auxiliaries to be
transported safely, chap. 2. It is not suitable or
approved for lifting the complete equipment to
which the engine is attached.
3.3. Notes on installation
The „Guide to selecting and installing an engine“
contains all the necessary information on engine
applications if you have an engine which has not
yet been installed in equipment and still has to
be fitted or set up.
This guide is available from your local
HATZ service station.
Do not exceed the forces and torques
indicated on the speed adjustment
lever and the stop pin, otherwise you may
damage the stops and internal governor components. Figure 2.
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
The type plate is placed on the noise insulating
hood (Fig. 1, pos. 1) and includes the following
engine information (Fig. 3):
➀ engine type
➁ code (only for special equipment)
➂ engine number (also stamped on crankcase,
Fig. 4)
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 starting up for the first time
Engines are normally supplied dry, i.e. not containing fuel or oil.
4.1.1. Engine oil
Oil quality
CCMC- D4 - D5 - PD2 or
API - CD - CE - CF - CG or
SHPD
If engine oil of a poorer quality is used, reduce
oil change intervals to 150 hours of operation.
Oil viscosity
Select the viscosity class according to the
ambient temperature for cold starts (Fig. 5).
When adding oil or checking the oil level, the
engine must be horizontal.
– Remove oil filler screw and add engine oil,
Fig. 6.
Lubricating oil capacity: see Chapter 3.1.
– To check the oil level, remove the dipstick,
clean it - then screw it back in and finally
remove it again, Fig. 7.
Check the oil level on the dipstick and, if
necessary, top up to the max. level.
4.1.2. Version with oilbath air cleaner
– Take off oil reservoir „1“ and fill with engine oil
as far as the mark, Figs. 8 and 9.
– Insert the filter element into the oil reservoir
with the long end „2“ leading, Fig. 8.
– Attach the oil reservoir, making sure that
sealing ring „3“ is correctly seated and
fasteners „4“ are tight.
7
4.1.3. Fuel
Stop the engine before refilling the
fuel tank. Never refuel near a naked
flame or sparks which could start a fire. Don't
smoke. Use only pure fuel and clean filling
equipment. Take care not to spill fuel.
All diesel oils which satisfy the following specifications are suitable:
EN 590 or
DIN 51601 - DK or
BS 2869 A1 / A2 or
ASTM D 975 - 1D / 2D
– Remove fuel tank cap, Fig. 10.
– Fill the fuel tank at least half full with diesel oil,
Fig. 11.
The fuel system does not require to be bled
as this is done automatically.
– Replace fuel tank cap, Fig. 12.
At temperatures below 0 °C, winter-grade fuel
should be used or paraffin added to the fuel well
in advance.
4.2. Starting
Do not run the engine in closed or
badly ventilated rooms – danger of
poisoning! Before starting the engine, ensure
that no-one is in the danger area close to the
engine or equipment, and that all protective
guards are fitted.
4.2.1. Starting procedure
If possible, disengage the engine from any
driven equipment.
The auxiliary equipment should always be placed
in neutral.
– First of all set the speed adjuster to the STOP
position, Figures 13 and 14, then move it to
the starting position.
Speed adjuster, standard version
– Set speed adjustment lever „1“ either to 1/2
START or max. START position, as desired or
necessary (Fig. 13).
Starting at a lower speed will help to prevent
exhaust smoke.
Speed adjuster with pull rod
– Move speed adjuster to the „START/RUN“
position, Figure 14.
Never use starting sprays!
Fig. 15.
4.2.2. Recoil starter with decompression
device (down to –6 °C)
– Starting procedure, see Chapter 4.2.1
The engine has an automatic decompression
system, which allows for a start from any position. However, we would like to recommend the
following procedure:
– Pull the starting cable out by the handle until
you feel a slight resistance, Fig. 16.
– Let the cable run back; in this way the entire
length of the starting cable can be used to
start the engine.
– Devices which are not securely fastened
should be restrained with the foot.
– Grip the handle with both hands, Fig. 17.
8
Lowest ambient
temperature when
starting, in °C
0 up to –10 20 % –
–10 up to –15 30 % –
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %
Paraffin content for:
Summer Winter
fuel fuel
– Commence pulling the starting cable vigorous-
ly and at an increasing speed (do not jerk it
violently) until the engine starts, Fig. 18.
On engines with an electric start system the
recoil starter also acts as an emergency-starter.
In this case the automatic decompression
system will switch back to normal compression
at a very low speed.
For this reason, please note that the starting
procedure described previously must be
followed exactly.
Note:
If after several attempts of starting the exhaust
begins to emit white smoke, move the speed adjustment lever to the STOP position and pull the
starting cable out slowly 5 times.
Repeat the starting procedure, Chapter 4.2.1.
4.2.3. Recoil starter without decom-
pression device (special version)
For use in regions with ambient temperatures of
–18 °C or lower, the engines are supplied without a decompression device.
At such low temperatures, only the electric
starter should be used.
The recoil starter serves as an emergency
starting device at higher temperatures (–6°C or
above).
– Prepare the engine for starting;
see Chapter 4.2.1.
– Pull out the handle with the cord slowly until
compression resistance is clearly felt; Fig. 16.
– Continue to pull slowly but with greater force
until the resistance becomes noticeably less
(compression overcome).
– Now let the cord run back - the engine is in
the correct starting position.
In this way the engine can be accelerated
through about one and a half revolutions with
the starting cord, to overcome compression resistance and achieved the required momentum
for starting.
– Support equipment with the foot if it is too
light in weight or liable to tip over.
– Take hold of the handle with both hands;
Fig. 17.
– Pull the starting cord up forcefully and at an
increasing speed (but do not jerk it) - the engine should then start.
4.2.4. Electric starter
– For starting preparations, see Chapter 4.2.1.
– Insert the key and turn it to position I, Fig. 19
and Fig. 20.
Depending upon the model, the battery charge
telltale „2“ and the oil pressure warning light „3“
will come on.
– 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, see chapter 6.
– Turn the key to position II.
– Release the key as soon as the engine runs.
The starting key must spring back to position I
and remain there during engine operation.
– The battery charge and oil pressure lights
should extinguish directly after the engine
starts. The display lamp „1“ lights up to show
that the engine is running.
– Prior to starting up again, the key has to be
returned to position 0. When the engine is
running the starter repeat lock in the ignition
switch will prevent the starter from engaging
and suffering damage.
9
Preheater system (optional extra)
When starting a cold engine, the preheat indicator „5“ will light, Fig. 19 and Fig. 20.
– Start the engine immediately after the light
goes out.
Fuel shut-off valve, stop solenoid
(additional equipment)
As soon as the starting key is at Position I, fuel
shut-off valve „1“ is electrically released; Fig. 21.
The fuel feed to the injection pump is then open
and the engine is ready to start.
When the engine is running, turning the starting
key to position 0 closes the cut-off valve and interrupts the fuel supply to the injection pump, so
that the engine stops; Chapter 4.3.
This shut-off valve is also used for the automatic
electrical shutdown system.
Emergency start
If the shut-off valve is blocking the fuel supply
as a result of an electrical fault and the engine
therefore cannot be started, an emergency start
can be attempted.
Proceed as follows for this:
– Turn the emergency start lever „1“ approx.
180° counter-clockwise as far as its stop,
using suitable pliers (the lead seal wire will
break off); Fig. 22.
– As soon as the emergency start lever is in the
starting position, the electric starter or recoil
starter can be used; Chapter 4.2.2 and 4.2.3.
The oil level must always be checked before an
emergency start, as insufficient oil pressure
can lead to complete damage of the engine
within a very short time.
After this, the engine can only be
stopped with the starting key in the
emergency operating mode if the emergency
starting lever is first turned back clockwise to
the stop position.
Immediately after a period of emergency running, ascertain the cause of the fault and have it
rectified; Chapter 6.
Have the emergency-starting lever sealed once
again by a HATZ service point.
When the automatic electrical shutdown system
is used, the emergency start described above
means that liability for risks must be accepted
by the operator (not covered by our warranty!)
In case of difficulty contact the nearest HATZ
service point.
Automatic electrical shutdown system
(additional equipment)
Engines with the automatic shutdown system
can be recognised by the externally located instrument box with preheat indicator „5“, Fig. 20.
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. 20, positions 2 - 4) will come on.
After the engine has stopped, the display continues to glow for about 12 seconds.
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.).
10
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