Hatz Diesel 1B20 User manual

INSTRUCTION BOOK
433 802 07 - ENG - 10.05 - 3
Printed in Germany 33
1B 20
1B 27
1B 30
1B 40
1B 50

A new HATZ Diesel engine - working 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 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 mainte-
nance 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 M00.
We reserve the right to make modifications in the course of technical progress.
MOTORENFABRIK HATZ GMBH & CO KG
1

Page
1. Important safety notes
when operating the engine 3
2. Description of the engine 5
3. General notes 6
3.1. Technical data 6
3.2. Transport 7
3.3 Notes on installation 7
3.4. Load on engine 7
3.5. Type plate 7
4. Operation 8
4.1. Prior to first-time start-up 8
4.1.1. Engine oil 8
4.1.2. Version with oilbath air cleaner 9
4.1.3. Fuel 9
4.2. Starting 10
4.2.1. Preparations for starting 10
4.2.2. Recoil starter 12
4.2.3. Electric starter 13
4.3. Stopping the engine 15
5. Maintenance 17
5.1. Maintenance chart 17
5.2. Maintenance every 8–15
operating hours 19
5.2.1. Checking engine oil level 19
5.2.2. Check air intake area for
combustion and cooling 19
5.2.3. Check air cleaner maintenance
indicator 20
5.2.4. Checking the water trap 20
Page
5.3. Maintenance every 250
operating hours 21
5.3.1. Oilbath air cleaner maintenance 21
5.3.2. Changing engine oil 22
5.3.3. Checking and adjusting
valve clearances 23
5.3.4. Cleaning cooling air area 24
5.3.5. Checking screw connections 24
5.3.6. Cleaning the exhaust mesh inlet 25
5.4. Maintenance every 500
operating hours 26
5.4.1. Renewing fuel filter 26
5.4.2. Air cleaner maintenance 27
5.5. Maintenance every 1000
operating hours 29
5.5.1. Cleaning the oil filter 29
6. Malfunctions – causes – remedies 31
7. Work on the electrical system 35
8. Storage out of use 35
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.

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 sys-
tems.
– 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 service station, 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
2
8910
911 12 13 14
15
16
17
18
19
20
21
3
4
6
5
7
1 22
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 41, Pos. 1)
21 Fuel tank cap
22 Noise insulating hood

3. General notes
3.1. Technical data
1) These values are intended as an approximate guide. The max. marking on the dipstick is the deter-
mining factor, Fig. 7.
2) Depending on model (see maintenance charts, chapter 5.1).
3) Exceeding these limits causes engine breakdown.
Tightening torques
Item Nm
Oil drain plug 50
6
Type 1B20 1B27 1B30 1B40 1B50
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 1 1 1 1 1
Bore / stroke mm 69 / 62 74 / 62 80 / 69 88 / 76 93 / 76
Displacement cm3232 267 347 462 517
Lubricating oil capacity
without oil sump
with oil sump
l, approx.
l, approx.
0.9 1)
2.6 1)
0.9 1)
–
1.1 1)
2.8 1)
1.5 1)
3.2 1)
1.5 1)
–
Difference between
“max” and “min” levels
without oil sump
with oil sump
l, approx.
l, approx.
0.5 1)
1.6 1)
0.5 1)
–
0.5 1)
1.8 1)
0.8 1)
2.2 1)
0.8 1)
–
Lubricating oil consumption
(after running in) max. 1 % 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 0.20 0.10 0.10 0.10 0.10
or automatically 2)
Max. tilt angle in operation,
in direction
Flywheel 25° down 3)
all other directions 35° 3)
Weight (incl. fuel tank, air-cleaner,
exhaust silencer, recoil starter and
electric starter)
kg,
approx. 33 34 40 55 56
Battery capacity Amp/h max. 12 V / 60 Amp/h

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.
2
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 com-
ponents.
3.4. Load on engine
Operating the engine for a lengthy period off-
load 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 signifi-
cantly higher load for a short period before
switching it off.
F<15 N STOP
76.5°
STOP START
F 30 N
M 2. 3 Nm
<
<
3.5. Type plate
3
The type plate is placed on the noise insulating
hood (Fig. 1, pos. 1) and includes the following
engine information:
➀engine type
➁code (only for special equipment)
➂engine number (also stamped on crankcase,
Fig. 4)
➃max. 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
Engine serial number on crankcase
MOTORENFABRIK HATZ KG
D-94099 RUHSTORF
GMBH
CO
+
GMBH
CO
+
TYP KENNZ.
MOTOR / FABRIK NO. ABE /AUSF.
MIN NH PV CM
MADE IN GERMANY
-1 3
7

4. Operation
4.1. Before starting up for the
first time
Engines are normally supplied dry, i.e. not con-
taining fuel or 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
Select the viscosity class according to the
ambient temperature for cold starts.
-40
-30
-20
-10
0
10
20
30
40
50
10 4
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
When adding oil or checking the oil level, the
engine must be horizontal.
6
– Remove oil filler screw and add engine oil.
Lubricating oil capacity: see Chapter 3.1.
7
– To check the oil level, remove the dipstick,
clean it - then screw it back in and finally
remove it again.
Check the oil level on the dipstick and, if
necessary, top up to the max. level.
max.
8

4.1.2. Version with oilbath air cleaner
8
9
– 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.
2444 / 5
2440 / 10
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 fuels which satisfy the following speci-
fications are suitable:
EN 590 or
BS 2869 A1 / A2 or
ASTM D 975 - 1D / 2D
10
– Remove fuel tank cap.
2439 / 12
9

11
– Before the first start or if the fuel tank has
been run dry, completely fill the fuel tank with
diesel. The bleeding of the fuel system is auto-
matically.
Note:
If a double fuel filter system is provided
(Chapter 5.4.1), wait for a short time after re-
plenishing fuel (approx. 1 to 2 minutes) for
automatic bleeding to be completed.
12
– Close and fix fuel tank cap.
2439 / 16
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. Preparations for starting
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.
Lowest ambient
temperature when
starting, in °C
Paraffin content for:
Summer
fuel
Winter
fuel
0 up to –10
–10 up to –15
–15 up to –20
–20 up to –30
20 %
30 %
50 %
–
–
–
20 %
50 %
10

Speed adjuster, standard version
13
– Set speed adjustment lever „1“ either to 1/2
START or max. START position, as desired or
necessary.
Starting at a lower speed will help to prevent
exhaust smoke.
Speed adjuster with pull rod
14
– Move speed adjuster to the „START/RUN“
position.
Now, the engine is ready for starting.
15
Never use starting sprays !
Important !
After long-time standstill (approx. 6 months or
even longer) or first operation, operate engine
with low adjusted speed and without load for
approx. 20 sec. after start. This measure assures
a lubrication of all bearings before increasing
speed and load.
It also prevents an insufficient lubrication.
050 145 00
11

4.2.2. Recoil starter (down to – 6 °C)
– For starting preparations, see Chapter 4.2.1.
Starting procedure
16
– Pull the starting cable out by the handle until
you feel a slight resistance.
– 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.
17
– Grip the handle with both hands.
18
– Commence pulling the starting cable vigorous-
ly and at an increasing speed (do not jerk it
violently) until the engine starts
Note:
If after several attempts of starting the exhaust
begins to emit white smoke, move the speed ad-
justment lever to the STOP position and pull the
starting cable out slowly 5 times.
Repeat the starting procedure, Chapter 4.2.1.
12

4.2.3. Electric starter
– For starting preparations, see Chapter 4.2.1.
19
20
– Insert the key to its stop 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.
1
2
3
4
5
– 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.
Preheater system (optional extra)
When starting a cold engine, the preheat indica-
tor „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)
21
As soon as the starting key is at Position I,
fuel shut-off valve „1“ is electrically released.
The fuel feed to the injection pump is then open
and the engine is ready to start.
13

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:
22
– For emergency starting, turn the lever at fuel
shut-off solenoid „1“ anti-clockwise by at least
90° using suitable pliers. The lead seal wire
will break off.
– 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.
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 run-
ning, 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 (Motorenfabrik HATZ assumes
no liability).
In case of difficulty contact the nearest HATZ
service point.
Automatic electrical shutdown system
(additional equipment)
Model with error memory
This is characterized by a brief flashing of all
pilot lamps once the starter key has been turned
to position I (Fig. 19 and 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 contin-
ues to glow for about 12 seconds.
The electrical device then switches itself off au-
tomatically.
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 6.2).
The display light goes out when the engine is
next started.
14

Model without error memory
This model has no specific characteristic which
appears externally. If the engine stops immedi-
ately after starting, this indicates a reaction of
a monitoring element of the automatic shut-off
feature. Before performing further starting at-
tempts, locate and eliminate the malfunction
(Chapter 6.2).
Even with automatic shutdown monitoring the
oil level must be checked every 8 – 15 operat-
ing hours (Chapter 5.2.1.).
4.3. Stopping the engine
Speed adjuster, standard version
23
– Move the speed adjustment lever „1“ back
to the STOP position. The engine cuts out.
Note:
Engines with a fixed lower idling speed cannot
be switched off using the speed adjustment
lever. See the paragraph entitled „Other ways of
switching off the engine“.
Speed adjuster with pull rod (optional extra)
24
– Move the speed adjuster to the „STOP“ posi-
tion and press it until the engine cuts out.
15

Other ways of switching off the engine
1. Fuel shut-off valve, stop solenoid
(optional extra)
25
26
– Turn ignition key to the 0 position. The engine
cuts out, Fig 25 and Fig. 26.
1
2
3
4
5
2. Stop pin (optional extra)
27
– Press the stop pin until the engine cuts out,
also see Fig. 23, position 2.
– Once the engine has cut out, release the
pin „2“ and ensure that it returns to its initial
position.
Depending upon the model, the battery charge
indicator „2” and oil pressure warning indicator
„3“ will come on again after the engine comes to
a stop, Fig. 25 and Fig. 26.
– Turn the key to position 0 and remove it.
All the indicator lights must go out, Fig. 25
and Fig. 26.
Note:
Failure to return the starter key to position 0
may result in the battery being totally
discharged.
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.
05221301
16

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 the
engine and all protective guards fitted again.
Before starting the engine, ensure that there are no persons in the danger area close to the
engine or equipment.
5.1. Maintenance chart
17
Maintenance interval Maintenance work required Chap.
8- 15
Every 8 – 15
operating hours,
or before each
daily start-up
Check oil level.
Examine the lower section of the oilbath air cleaner
to ensure correct oil level and freedom from con-
tamination; change the oil if it contains sludge.
On version with cyclone-type dust trap, empty the
dust collector.
Check combustion and cooling air intake zone.
Check air-cleaner maintenance indicator.
Check the water trap.
5.2.1.
4.1.2.
5.3.1.
5.3.1.
5.2.2.
5.2.3.
5.2.4.
250
Every 250
operating hours
Oilbath air cleaner maintenance.
Change engine oil.
Check and adjust valve clearances.
(Not applicable with automatic self adjusting valve
clearance models, see next page)
Clean cooling air area.
Check screw connections.
Clean mesh insert for exhaust.
5.3.1.
5.3.2.
5.3.3.
5.3.4.
5.3.5.
5.3.6.
500
Every 500
operating hours
Change fuel filter element.
Dry-type air cleaner maintenance.
5.4.1.
5.4.2.
1000
Every 1000
operating hours Clean the oil filter. 5.5.1.

Depending whether the engine is equipped with
or without automatic valve clearance adjustment
one of the illustrated maintenance plans is in-
cluded. This label should be affixed to the engine
or equipment in an easily visible position. The
maintenance chart governs the maintenance in-
tervals.
On new or reconditioned engines, after the
first 25 operating hours, always
– Change engine oil, Chapter 5.3.2.
–
Check valve clearances and adjust if necessary,
Chapter 5.3.3.
– Examine screw connections, chapter 5.3.5.
Do not tighten the cylinder head fastening.
If the engine is not used frequently, change the
engine oil after 12 months at the latest, regard-
less of the actual number of hours it has been in
operation.
18
AUTOM.
8-15 250
052 502 00
OIL
OIL
-40
-30
-20
-10
0
10
20
30
40
50
10 4
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
W
1B..
500
1000
Model without automatic valve clearance adjustment.
Model with automatic valve clearance adjustment.

5.2. Maintenance every 8 – 15
operating hours
5.2.1. Checking engine oil level
To check the oil level, the engine must be
standing level and be switched off.
– Remove any dirt from the oil dipstick area.
– Remove dipstick and clean it.
28
– To check the oil, screw the dipstick back in
and then remove it again.
– Check the dipstick oil level and, if necessary,
add oil to the max. mark, Chapter 4.1.1.
5.2.2 Check air intake area for
combustion and cooling
Heavy contamination is an indication that in-
creased dust accumulation necessitates a corre-
spondingly shorter maintenance interval,
Chapter 5.3.1., 5.3.4. and 5.4.2.
max.
29
– Check air intake points for severe blockage
due to leaves, heavy dust accumulation etc.,
and if necessary clean them.
30
– For models fitted with cyclone, additionally
check if inlet point „1“ is clear. Make sure that
dust outlet „2“ is not blocked and clean if
necessary.
19