Hatz Diesel Engine Service Manual

33 1D 41. 1D 42. 1D 50. 1D 81. 1D 90. 000043320209-ENG-12.09-3 Printed in Germany Translation ofthe ORIGINAL INSTRUCTION BOOK

1 A new HATZ dieselengine is ready to work foryou This engine is intended only forthe purpose determined and tested by the manufacturerofthe equipmentin which itis installed.Using itin any othermannercontravenes the intended purpose. Fordangerand damage due to this,Motorenfabrik HATZ assumes no liability.The risk is with the useronly.Use ofthis engine in the intended mannerpresupposes compliance with the maintenance and repairinstructions laid down forit.Noncompliance leads to engine breakdown. Please study this Instruction Book before you startthe engine forthe firsttime:itwill help you to avoid accidents,to operate the engine correctly,to perform maintenance work and to keep the engine operating atfull efficiency fora very long tim e. Please pass this Instruction Manual on to the nextuserorto the following engine owner. Always have service work performed by qualified specialists.To this effect,we recommend thatyou consultone ofthe 500 HATZ service stations.There,yourengine is repaired by staffwho constantly undergo training and who use both originalHATZ spare partsand HATZ tools.The world-wide HATZ service network is also available to you forconsultation and spare parts supply. Forthe address ofyournearestHATZ service station,please referto the attached listorthe internet under:www.hatz-diesel.com The installation ofinappropriate spare parts m ay cause problems.W e cannnotacceptany liability for damage orconsequential damage resulting therefrom. Thus,we recommend thatyou use originalHATZ spare parts.These parts are manufactured following the strictHATZ specifications and ensure,thanks to theirperfectfitand function,maximum operating reliability.Forthe reference number,please consultthe attached spare partlistorthe internet under:www.hatz-diesel.com.Please take the complete spare parts kits in Table M00 into account. In the interests oftechnical progress we reserve the rightto introduce modifications. MOTORENFABRIK HATZ GMBH & CO KG

Importantnotes on safe operation ofthe engine 3 2. Description ofthe engine 5 3. Generalinformation 7 3.1. Technical data 7 3.2. Transport 8 3.3 Instructions forinstallation 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 aircleaner 9 4.1.3.Fuel 10 4.1.4.Mechanical oil pressure monitor 11 4.2. Starting the engine 12 4.2.1.Preparations forstarting 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 – 15hours ofoperation 21 5.2.1.Check engine oil level 21 5.2.2.Check airintake point 21 5.2.3.Aircleanerblockage indicator 21 5.2.4.Checking cooling airzone 22 5.2.5.Checking the watertrap 22 Page 5.3. Maintenance every 250hours ofoperation 23 5.3.1.Oilbath aircleanermaintenance 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 airsystem 26 5.3.5.Checking threaded connections 27 5.3.6.Cleaning mesh insertin exhaust silencer 27 5.4. Maintenance every 500hours ofoperation 28 5.4.1.Renewing fuel filter 28 5.4.2.Dry-type aircleanermaintenance 29 6. Malfunctions – Causes – Remedies 31 7. W ork on the electricalsystem 35 8. Protective treatment 35 9. Declaration forIncorporation 36 2 This symbol draws attention to im portantsafety precautions. Please comply with them mostcarefully in orderto avoid any risk ofinjury to persons or damage to m aterials. General legal requirements orsafety regulations issued by the competentauthorities or industrial accidentinsurers are also applicable. Contents

3 1. Importantnotes on safe operation ofthe engine HATZ diesel engines are economical,strongly builtand long-lasting.They are therefore frequently chosen forcommercially and industrially operated equipmentand machinery. Since the engine forms partofthe finished equipmentormachine,its manufacturerwill 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 mannerin which the engine is installed and its intended application,the equipment manufactureroroperatormay have to attach additional safety devices and prohibitpotentially hazard- ous aspects ofoperation,forexample: – Parts ofthe exhaustsystem as well as the surface ofthe engine are ofcourse hotduring operation ofthe engine,butalso when itis still cooling down afteruse,and mustnotbe touched. – Faulty wiring orincorrectoperation ofelectrical equipmentmay lead to sparks forming,and must be avoided as a potential fire hazard. – Rotating parts mustbe shielded againstaccidental contactwhen the engine is installed in other equipmentormachinery. Guards are available from HATZ to protectbeltdrives,cooling fans and generators. – Before attempting to startthe engine itis essential to have studied the starting information in the Instruction Book;this is particularly importanton engines started with a starting handle. – M echanical starting devices mustnotbe used by children orpersons ofinsufficientphysical strength. – In orderto benefitfrom the advantages ofthe starting handle with kick-back damping,itmustbe used precisely as recommended in this Instruction Book. – Before starting the engine,ensure thatall the specified protective guards are in place. – The engine mustonly be operated,serviced orrepaired by persons who have received the appro- priate training. – Keep the starting handle and the key outofreach ofunauthorized persons. – Neverrun the engine in closed orbadly ventilated rooms. Do notbreath in emissions -dangerofpoisoning! – Also fuel and lubricants could contain poisonous components.Please follow the instructions ofthe m ineral oil producer(safety data sheets).

4 Importantnotes on safe operation ofthe engine – Stop the engine before performing any maintenance,cleaning-and repairwork. – Stop the engine before refuelling. Neveradd fuel neara naked flame ora source ofsparks. Don’tsmoke.Don’tspill fuel. – Keep explosive materials as well as flammable materials away from the engine because the exhaust gets very hotduring operation. – W earclose-fitting clothing when working on a running engine. Please don’twearnecklaces,bracelets orany otherthings which you could getcaughtwith. – Please pay attention to all advice-and warning stickers placed on the engine and keep them in legible condition.In case a label has come offoris no longerclearly legible,itmustbe replaced imme- diately.To this effect,please contactthe HATZ service stationin yourarea. – Note thatany unauthorized modification to the engine absolves its manufacturerfrom liability for the consequences. Regularservicing in accordance with the details provided in this Instruction Book is essential to keep the engine operating reliably. In case ofdoubt,always consultyournearestHATZ service stationbefore starting the engine.

5 2. Description ofengine 1D41 •1D42 • 1D50 • 1D81 • 1D90 S /Zengines 1 2391 / 12 2391 / 7 1 Cooling airinlet 2 Dry-type aircleaner 3 Decompression lever 4 Stop lever 5 Cooling airoutlet 6 Silencer(muffler) 7 Guide sleeve forstarting handle 8 Cylinderhead cover 9 Cold-startoil metering device 10 Suspension lug 11 Tank fillercap 12 Oil drain plug,governorhousing 13 Oil drain plug,governorside 14 Speed control lever 15 Oil fillerpipe and dipstick 16 Fuel filter 17 Oil filter 18 Type plate 19 Tank drain plug 20 Combustion airintake

6 Description ofengine Fully-encapsulated version 1D41C • 1D42C • 1D81C • 1D90C engines 2 1 Capsule 2 Decompression lever 3 Cold-startoil metering device 4 Combustion and cooling airintake 5 Oil filter 6 Cleaning hatch 7 Side panels 8 Hold forstarting handle 9 Suspension lug 10 Silencer(muffler),encapsul. 11 Cooling airoutlet 12 Battery connection and central plug forelectrical system 13 Stop lever 14 Speed control lever 15 Oil drain plug 16 Oil fillerand dipstick 17 Type plate 2392 / 1 2392 / 4

7 3. Generalinformation 3.1. Technicaldata 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 M ode ofoperation air-cooled four-stroke diesel engine Combustion method Direct-fuel injection Numberofcylinders 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 contentwithoutfilter 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 ofoil between „max“and „min“marks approx.L 0.4 1) 0.4 1) 0.5 1) 0.9 1) 0.9 1) Consumption oflubrication oil afterrunning-in period approx.1 % offuel consumption atfull load Engine oil pressure Oil termperature100 ± 20 °C m in. 0.6 barat850 r.p.m. Direction ofrotation looking atthe flywheel counterclockwise Valve clearance at10 -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 M ax.angle from vertical in any direction (continuous operation) m ax. 30° 2) 30° 2) 30° 2) 25° 2) 25° 2) W eight(incl.fuel tank,air-cleaner, exhaustsilencerand 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 M odel S:non-encapsulated,normal system ofbalancing Z:non-encapsulated,add.system ofbalancing C:SILENT PACK,add.system ofbalancing

3.2. Transport A lug is provided on top ofthe engine as standard equipment,so thatthe engine can be lifted safely.Itis notsuitable for lifting complete machines orsimilarwith the engine attached,and this is strictly prohibited. (See Chapter2.) 3.3. Instructions forinstallation The „Manual forSelection and Installation ofEn- gines“contains all the information you need if yourengine has notyetbeen installed on orin the equipmentitis intended to drive,orsetup in its correctoperating position.You can obtain a copy ofthis manual from yournearestHATZ service station. Moreover,we would like to pointoutthatin this case,commissioning is prohibited until ithas been verified thatthe m achine into which this engine is to be incorporated complies with the regulations ofthe EC M achinery Directive. Referalso to Chapter9 „Declaration forIncorpo- ration“. 3 The permitted loads and elements on the speed adjusting leverand the stop levershould be observed as an exess can lead to damage to the contacts and innergovernor parts. 3.4. Load on engine Operating the engine fora lengthy period off- load oratvery low loads can affectits running quality. W e therefore recommend a minimum engine load of15 % .Ifoperated atsuch low loads,itis bestto operate the engine ata significantly high- erload fora shortperiod before switching itoff. 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 forspecial equipment) ➂ engine number ➃ max.engine speed Forany offeras well as spare parts orders itis 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 initialstart-up Engines are normally delivered withoutfuel and oil. 4.1.1.Engine oil Qualified are all trademark oils which fulfil at leastone ofthe following specifications: ACEA – B2 /E2 ormore significant API– CD /CE /CF /CF-4 /CG-4ormore significant. Ifengine oil ofa poorerquality is used,reduce oil change intervals to 150 hours ofoperation. Oilviscosity 5 Please selectthe recommended viscosity depending on the ambienttemperature atwhich the engine is operated. Inappropriate engine oilmay shorten the engine’s service life significantly. The engine mustbe in a horizontal position before adding oil orchecking the oil level. 6 – Pull outdipstick „1“and add engine oil ofthe correctspecification and viscosity up to the „max“ markon the dipstick;(Chapter3.1.). 4.1.2.Oilbath aircleaner 7 – Take offthe oil reservoirand fill itup to the mark „1“using engine oil. – Attach the oil reservoir,making sure thatseal- 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 15 W/40 30 40 122 10W 9

Hatz Diesel Engine Service Manual

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