INSTRUCTION BOOK 1B 20 1B 30 1B 40 433 802 04 - ENG - 01.01 - 2.
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.
Contents Page 1. Important safety notes when operating the engine 3 2. Description of the engine 5 3. 3.1. 3.2. 3.3 3.4. 3.5. General notes Technical data Transport Notes on installation Load on engine Type plate 6 4. 4.1. 4.2. 4.3. Operation Prior to first-time start-up Starting Switching off - Stopping 7 5. 5.1. 5.2. 5.3. 5.4. 5.5.
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.
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.
2. Description of the engine 2 1 22 21 20 19 3 18 4 17 5 16 6 15 7 8 9 10 9 11 12 13 14 Fig. 1 1 2 3 4 5 6 7 8 9 10 11 12 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.
3. General notes 3.1. Technical data Type 1B20 Design 1B30 1B40 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 cm3 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.
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. 4.1. Before starting up for the first time 4.1.1. Engine oil Notes on installation 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.
4.1.3. Fuel 4.2.1. Starting procedure 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. 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.
– Commence pulling the starting cable vigorously and at an increasing speed (do not jerk it violently) until the engine starts, Fig. 18. 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. On engines with an electric start system the recoil starter also acts as an emergency-starter.
Preheater system (optional extra) 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 starting a cold engine, the preheat indicator „5“ will light, Fig. 19 and Fig. 20. – Start the engine immediately after the light goes out.
4.3. Stopping the engine Note: Failure to return the starter key to position 0 may result in the battery being totally discharged. Speed adjuster, standard version – Move the speed adjustment lever „1“ back to the STOP position. The engine cuts out, Fig. 13. If operation of the engine is interrupted for any reason, or at the end of the working day, the starter key should be kept out of reach of unauthorised persons.
5. Maintenance Only carry out maintenance work with the engine switched off. Observe all relevant laws and regulations governing the handling and disposal of used oil, filters and cleaning agents. Protect the starting key against unauthorised use. On engines with an electric starter, disconnect the battery's negative terminal. When maintenance work has been completed, check that all tools have been removed from theengine and all protective guards fitted again.
8 -15 0 14 -10 -4 -20 -22 -30 -40 -40 40 250 OIL 500 10 32 30 20 50 15W/40 68 OIL: SAE... 10W/40 30 5W/40 40 86 10W/30 °C 50 104 10W °F 122 EX 0.1 mm 0.004 " 5W/30 IN 0.1 mm 0.004 " OIL 051 104 02 1000 1B20 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.
5.2. Maintenance every 8 - 15 operating hours 5.2.4. 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. 5.2.1. Checking engine oil level To check the oil level, the engine must be standing level and be switched off. – Loosen hexagon screw „1“ with approx. 3-4 rotations; Fig. 25. – Remove any dirt from the oil dipstick area.
5.3. Maintenance every 250 operating hours – Clean the oil drain plug „1“, fit a new washer „2“, insert and tighten. Tightening torque: 50 Nm. 5.3.1. Oilbath air cleaner maintenance – Add engine oil, Chapter 4.1.1. – Take off oil reservoir „1“ and clean it, Fig. 27. – Rinse out filter element „2“ in diesel oil; allow it to drip thoroughly and wipe it down before re-assembling the air cleaner. 5.3.3. Checking and adjusting valve clearances – If severely contaminated, clean filter housing „3“.
– Re-attach parts previously removed from engine. Do not forget: replace the rubber cap at the inspection hole cover. 5.3.6. Cleaning the exhaust mesh inlet Exhaust system components will naturally be hot and must not be touched while the engine is running or until it has cooled down after being stopped. – Carry out a brief test run, then check the cover for leaks. – Unscrew hex nut and remove the exhaust mesh insert, Fig. 37. 5.3.4.
5.4. Maintenance every 500 operating hours – Fill the fuel tank with diesel oil; Chapter 4.1.3. Air is vented from the fuel system automatically. 5.4.1. Renewing fuel filter – Check the fuel filter and lines for leaks after a short test run. The maintenance intervals for the fuel filter are dependent upon the purity of the diesel oil being used and, if necessary, may have to be reduced to 250 hours. 5.4.2.
Checking the filter cartridge 5.5. Maintenance every 1000 operating hours – Check filter cartridge's gasket surface „1“ for damage, Fig. 46. 5.5.1. Cleaning the oil filter – Check the filter cartridge for cracks or any other type of damage to the paper filter by holding it inclined towards the light or by shining a light source through it. The oil filter should be cleaned at the same time as the engine oil is changed, since oil escapes when the filter is removed.
6. Malfunctions – causes and remedies Malfunctions Possible causes Remedy Chap. 6.1. Engine does not start, or not immediately, but can be turned over easily as usual. Speed control lever in stop or idle position. Move lever to START position. 4.2.1. Engine shutdown pin in STOP position. Move to operating position by pulling the pin gently. 4.3. No fuel in the injection pump. Add fuel.
Malfunctions Possible causes At low temperatures: Starting speed below 400 min-1 - Viscosity of oil too high. - Battery charge too low. Remedy Chap. Change lubricating oil and add oil of the correct viscosity class. 5.3.2. 4.1.1. Check the battery, if necessary contact a service station. 7. If equipped with a stop solenoid or automatic electrical shutdown system (additional equipment) Solenoid faulty and/or fault in the electrical system. 6.2. Engine fires but does not run.
Malfunctions Possible causes Remedy Chap. 6.4. Engine cuts out of its own accord during operation. Fuel supply interrupted - Tank has run empty. - Fuel filter blocked. - Tank venting inadequate. Add fuel. Change fuel filter. Ensure adequte tank venting. 4.1.3. 5.4.1. Mechanical faults. Contact a HATZ service station. One of the automatic shutdown's monitoring elements has initiated a stop signal. Localise the monitoring element responsible and clear the fault, or contact a HATZ service station.
Malfunctions Possible causes Remedy Chap. 6.7. Engine becomes very hot. Indicator lamp for cylinder temperature (optional extra) comes on. Too much lubricating oil in engine. Drain off lubricating oil as far as upper mark on dipstick. 5.3.2. Inadequate cooling: - Contamination of entire cooling air zone. Clean cooling air zone. 5.3.4. 6.8. Moisture condensate emerging from exhaust. - Air duct panels not properly sealed.
7. The relevant circuit diagrams are enclosed with the engine if it is equipped with an electrical system. Additional circuit diagrams can be supplied to order. Electrical systems that do not comply with HATZ circuit diagrams are excluded from warranty. 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 eyes, skin and cloth against the corrosive battery acid.
MOTORENFABRIK HATZ+GMBH CO KG D-94099 RUHSTORF TYP F < 15 N STOP F < 30 N KENNZ. MOTOR / FABRIK NO. ABE /AUSF. MIN-1 PV NH CM 3 M < 2.3 Nm 76.5° STOP START MADE IN GERMANY 4 3 20 50 10 32 0 14 -10 -4 -20 -22 -30 -40 -40 5 max. 2438 / 1 6 7 40 68 30 30 15W/40 40 86 10W/40 50 104 10W/30 122 OIL: SAE...
2440 / 10 8 2439 / 12 10 2444 / 5 9 2439 / 9 11 2439 / 16 12 13
050 145 00 14 2438 / 17 16 15 2441 / 3 17 2444 / 17 18 19
1 2 3 4 5 20 21 22 23 2438 / 12 1 1 24 25
1 2444 / 3 26 2440 / 13 28 27 2445 / 3 29 2443 / 12 30 31
2 1 2442 / 18 32 33 3 2 1 2 3 2119 / 3 34 35 36 37 2442 / 6
2441 / 12 38 39 40 41 42 43 2441 / 8
1 2442 / 3 44 45 2444 / 10 46 47 48 49 2445 / 10
50 51
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.
