Hatz 1D90V User manual

CREATING POWER SOLUTIONS.
OPERATOR’S MANUAL
Diesel engine
Hatz Diesel
1D90V | 1D90W
www.HATZ-DIESEL.com
INCLUDES SUPPLEMENTAL INFORMATION TO
THE OWNER’S MANUAL FOR MODEL YEAR 2016
EPA CERTIFIED NONROAD COMPRESSION-IG-
NITION ENGINES.
INCLUDES SUPPLEMENTAL INFORMATION FOR
THE USE OF EPA CERTIFIED ENGINES WITHIN
CALIFORNIA.

1D90V, 1D90W Table of contents
HATZ 3Operator’s Manual
Table of contents
1 Notices ................................................................................................................. 5
2 General information ............................................................................................ 6
3 Safety ................................................................................................................... 7
3.1 General information............................................................................................... 7
3.1.1 Intended use and foreseeable misuse .................................................................. 7
3.1.2 Machine user or machine manufacturer obligations ............................................. 8
3.1.3 Representation of safety notes ............................................................................. 9
3.1.4 Meaning of safety symbols.................................................................................. 10
3.2 Safety notes ........................................................................................................ 12
3.2.1 Operational safety ............................................................................................... 12
3.2.2 Machine-specific safety instructions for operation .............................................. 15
3.2.3 Machine-specific safety instructions for maintenance work ................................ 16
3.2.4 Electrical equipment............................................................................................ 18
3.3 Labels.................................................................................................................. 19
4 Technical data ................................................................................................... 21
4.1 Engine information and filling quantities.............................................................. 21
4.2 Engine type plate ................................................................................................ 22
4.2.1 Engine serial number .......................................................................................... 23
4.3 Physical operating conditions.............................................................................. 24
4.4 Engine oil ............................................................................................................ 24
4.5 Fuel ..................................................................................................................... 26
5 Engine design.................................................................................................... 27
6 Transport, assembly and commissioning ...................................................... 28
6.1 Transport............................................................................................................. 28
6.2 Installation notes ................................................................................................. 29
6.3 Preparations for commissioning.......................................................................... 30
6.4 Filling engine oil (first filling) ................................................................................ 30
7 Operation and use............................................................................................. 32
7.1 Safety notes ........................................................................................................ 32
7.2 Performing tests .................................................................................................. 33
7.3 Start preparation ................................................................................................. 33
7.3.1 Activating the mechanical oil pressure shut down device (option):..................... 34
7.3.2 Setting the speed control .................................................................................... 35
7.4 Starting the engine .............................................................................................. 36
7.5 Switching off the engine ...................................................................................... 41
7.5.1 Switching off the engine (mechanical) ................................................................ 41
7.5.2 Switching off the engine (electrical) .................................................................... 43
7.6 Checking the oil level and adding oil if necessary............................................... 44
7.7 Refueling ............................................................................................................. 46
7.8 Checking the water separator ............................................................................. 47

Table of contents 1D90V, 1D90W
4HATZ Operator’s Manual
7.9 Check the air filter warning indicator (option)...................................................... 49
8 Maintenance ...................................................................................................... 50
8.1 General maintenance instructions....................................................................... 50
8.2 Maintenance work ............................................................................................... 51
8.2.1 Maintenance notice label .................................................................................... 51
8.2.2 Maintenance plan................................................................................................ 52
8.2.3 Check the intake area of the combustion air....................................................... 54
8.2.4 Checking the cooling air area.............................................................................. 55
8.2.5 Changing the engine oil and oil filter ................................................................... 56
8.2.6 Checking and setting the tappet clearance ......................................................... 60
8.2.7 Cleaning the cooling air area .............................................................................. 62
8.2.8 Checking the screw connections......................................................................... 63
8.2.9 Changing the fuel filter ........................................................................................ 63
8.2.10 Maintaining the dry air filter ................................................................................. 66
8.2.11 Checking and cleaning the air filter cartridge ...................................................... 67
9 Faults.................................................................................................................. 69
9.1 Trouble shooting ................................................................................................. 69
10 Storage and disposal........................................................................................ 75
10.1 Storing the machine ............................................................................................ 75
10.2 Disposing of the machine.................................................................................... 77
11 Installation declaration ..................................................................................... 78
12 EPA CERTIFIED ENGINES................................................................................ 79
13 EPA CERTIFIED ENGINES WITHIN CALIFORNIA........................................... 87

1D90V, 1D90W Notices
HATZ 5Operator’s Manual
1 Notices
Contact data
© 2016
Motorenfabrik HATZ
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. [phone]
Fax [phone]
[email protected]
www.hatz-diesel.com
All rights reserved!
Copyright
The copyright for this Operator's Manual rests entirely with Motorenfabrik
HATZ, Ruhstorf.
This Operator's Manual may only be copied or distributed if written approval
has been received. This also applies to the copying or distribution of ex-
cerpts of the Operator's Manual. The same conditions apply to distribution of
the Operator's Manual to third parties in digital form.
Original Operator's Manual
This Operator's Manual was translated into multiple languages.
The German version is the original Operator's Manual. All other language
versions are translations of the original Operator's Manual.

General information 1D90V, 1D90W
6HATZ Operator’s Manual
2 General information
Information on the document
This Operator's Manual was created with due care. It is exclusively intended
to offer a technical description of the machine and to provide instructions on
commissioning, operating and maintaining the machine. When operating the
machine, the applicable standards and legal regulations as well as any in-
house regulations apply.
Before commissioning, during operation and before maintenance work is be-
gun on the machine, read the Operator's Manual carefully and keep it close
by for ready access.
Machine
This Operator's Manual describes the following machine.
Machine name HATZ diesel engine
Type number 1D90V, 1D90W
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the over 500 HATZ service stations. Trained spe-
cialists there will repair your machine with Hatz original spare parts and
with HATZ tools. The global HATZ service network is at your disposal to ad-
vise you and supply you with spare parts. For the address of the Hatz ser-
vice station nearest you, please see the directory included or visit the inter-
net at: www.hatz-diesel.com
Problems may occur if unsuitable spare parts have been installed. We can-
not accept responsibility for damage and secondary damage that result from
this.
We therefore recommend the use of genuine Hatz original spare parts.
These parts are manufactured according to strict Hatz specifications and
achieve maximum operational reliability through their perfect fit and function-
ality. The order number can be found in the enclosed spare parts list or on
the internet at: www.hatz-diesel.com
Exclusion of liability
The manufacturer cannot be held responsible for personal injury, damage to
property, or damage to the machine itself caused by improper use, foresee-
able misuse, or failure to follow or adequately follow the safety measures
and procedures described in this Operators Manual. This also applies to
changes made to the machine and the use of unsuitable spare parts.
Modifications, which serve technical improvement, are reserved.

1D90V, 1D90W Safety
HATZ 7Operator’s Manual
3 Safety
3.1 General information
Introduction
This chapter contains the information you need to work safely with this ma-
chine.
To prevent accidents and damage to the machine, it is imperative that these
safety instructions be followed.
Read this chapter carefully before beginning work.
3.1.1 Intended use and foreseeable misuse
Intended use
The machine described in this Operator's Manual fulfills the following func-
tions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See the chapter 11 Installation decla-
ration, page 78.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine into which the engine is installed.
Any other use is not intended and therefore not permitted. Violations com-
promise the safety of the personnel working with the machine. Responsibility
is not accepted by Motorenfabrik HATZ for damage resulting from this situa-
tion.
The operational safety of the machine is only guaranteed if it is used as in-
tended.
The intended use also includes observance of the instructions in this Opera-
tor's Manual to preserve the environment, including in the appendix for the
model year 2016 as per EPA Nonroad Diesel Engines.
Foreseeable misuse
The following is considered to be foreseeable misuse:
▪ Any use that varies from or extends beyond the uses specified above.
▪ Failure to comply with the instructions in this Operator's Manual.
▪ Failure to comply with the safety instructions.
▪ Failure to immediately eliminate malfunctions that impact safety before
continuing work with the machine (working with the machine when it is not
in perfect condition, either functionally or in terms of safety).
▪ Failure to perform the necessary inspection and maintenance work.
▪ Any unauthorized modification of or removal of safety equipment.
▪ Use of spare parts and accessories that are unsuitable or have not been
approved by HATZ.

Safety 1D90V, 1D90W
8HATZ Operator’s Manual
▪ Operation in flammable or hazardous environments.
▪ Operation in closed-off or poorly ventilated rooms.
▪ Installation of the machine in moving equipment (e.g. vehicles, trailers) or
in closed rooms without additional measures to handle supply air, extract
air, and exhaust gas.
▪ Improper operation at variance with DIN 6271 and DIN ISO 8528 (climate,
load, safety).
Residual risks
Residual risks result during daily use and in association with maintenance
work.
These residual risks will be pointed out in chapter 3.2.2 Machine-specific
safety instructions for operation, page 15 and in chapter 3.2.3 Machine-
specific safety instructions for maintenance work, page 16 as well as in the
further contents of the manual, directly in front of the descriptions or operat-
ing instructions concerned.
3.1.2 Machine user or machine manufacturer obligations
Machine manufacturer obligations
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines be-
fore installing the engine. These assembly instructions contain important in-
formation on how to safely install the engine and are available at your near-
est HATZ service station.
It is prohibited to start the engine before it is fully installed.
In addition, please note that it is prohibited to start up the machine before it
has been determined that the machine into which this engine is installed ful-
fills all safety-related requirements and legal regulations.
User obligations
The user is obliged to operate the machine when it is in perfect condition
only. The user must check the condition of the machine before use and en-
sure that any defects are eliminated before it is taken into service. Running
the machine while identified defects exist is not permitted. The user must
also ensure that all persons who work on the machine are familiar with the
contents of this Operators Manual.

1D90V, 1D90W Safety
HATZ 9Operator’s Manual
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood the Operator's Manual or must possess the qualifica-
tions necessary for working with this equipment, acquired in training/instruc-
tional courses. No one may work with the machine without the necessary
qualifications, even if for just a brief period.
The operating personnel must not be under the influence of drugs, medica-
tion or alcohol.
All work performed on the machine must be in compliance with the informa-
tion provided in the Operator's Manual.
Storing the Operator's Manual
This Operator's Manual is an integral component of the machine (also when
being sold). It must be stored in the direct vicinity of the machine and be ac-
cessible to personnel at all times.
3.1.3 Representation of safety notes
Overview
This machine has been designed and built according to state-of-the-art tech-
nology and the recognized safety standards. Despite these precautions,
risks exist when operating the machine and during maintenance work.
These risks are identified in this manual by means of safety notes.
The safety notes precede the related description or operating step.
Structure of the safety notes
The safety notes consist of:
▪ Danger symbol
▪ signal word
▪ Description of danger
▪ Possible consequences
▪ Preventative measures
General danger symbol
The general danger symbol is used to identify the danger of personal injury.

Safety 1D90V, 1D90W
10 HATZ Operator’s Manual
Signal words
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
Danger symbol/
signal word
Meaning
DANGER
This signal word is used to indicate imminently
dangerous situations which, if not avoided, will
lead to serious injury or death.
WARNING
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to serious injury or death.
CAUTION
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to minor or moderate injury.
CAUTION
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
NOTICE
This signal word indicates additional useful infor-
mation, such as operating tips and cross refer-
ences.
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this Operator's Manual.
Symbol Meaning
Smoking, fire, and open flames are prohibited!
Warning of personal injury!
Warning of hot surfaces!
Warning of flammable substances!

1D90V, 1D90W Safety
HATZ 11Operator’s Manual
Symbol Meaning
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
Warning of heavy loads!
Warning of environmental damage!
Comply with the Operator's Manual or additional documenta-
tion from other manufacturers or the user!
i
Additional information that is useful to the reader.

Safety 1D90V, 1D90W
12 HATZ Operator’s Manual
3.2 Safety notes
3.2.1 Operational safety
Introduction
This chapter contains all of the important safety instructions for personal pro-
tection and for safe and reliable operation. Additional, task-related safety in-
structions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury or danger of property dam-
age due to failure to comply with the Operator's Manual and
the safety instructions contained therein.
▪ As the user of the machine, you must ensure that all people
working on the machine are familiar with the content of this
Operator's Manual.
▪ Before working on the machine, read this Operator's Manual
carefully, paying special attention to the safety notes.
▪ Fulfill all required safety conditions before working on the
machine.
▪ Follow all general safety instructions as well as the specific
task-related safety instructions contained in the individual
chapters.
Using the machine
▪ Only operate the machine for the purposes described in chapter 3.1.1 In-
tended use and foreseeable misuse, page 7.
Compliance with other regulations
▪ Adhere to the applicable accident prevention regulations of the trade asso-
ciations.
▪ Comply with the regulations concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regula-
tions also apply when operating the machine.
Personal protective equipment
During operation and maintenance of the machine, personal protective
equipment must be available and must be used if necessary. The required
personal protective equipment is specified in the descriptions of the operat-
ing steps.

1D90V, 1D90W Safety
HATZ 13Operator’s Manual
Personal protective
equipment
Pictogram Function
Safety shoes Safety shoes offer protection
against:
▪ Slipping
▪ Falling objects
Hearing protection Hearing protection offers protec-
tion against ear injuries due to
excessive and constant noise.
Safety gloves Safety gloves protect the hands
against injury, e.g. from battery
acid.
Safety goggles
(with side protection)
Safety goggles protect the eyes
from flying objects (e.g. dust
particles, spraying liquids, spray-
ing acid).
Working clothes Wear close-fitting clothing. How-
ever, it must not restrict the
wearer's freedom of movement.
Warning labels and information signs on the machine
The warning labels and information signs on the machine must be followed
(see chapter "Labels" 3.3 Labels, page 19).
The warning labels and information signs must be kept legible and must be
replaced if necessary. For this purpose, contact your nearest HATZ service
station.
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians (see chapter 2 General in-
formation, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.
Safety equipment
Safety equipment must not be modified and must not be rendered ineffective
during normal operation.

Safety 1D90V, 1D90W
14 HATZ Operator’s Manual
General safety instructions
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in the Operator's Manual.
▪ Heed the warnings on the machine and in the Operator's
Manual.
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪ The personnel must have read and understood this Opera-
tor's Manual or must possess the qualifications necessary
for working with this equipment, acquired in training/instruc-
tional courses.
▪ Only qualified personnel is permitted to operate and main-
tain this machine.
▪ Failure to comply will cause the warranty to be void.
WARNING
Danger of injury from failure to follow the operating instruc-
tions and from performing unauthorized tasks on the ma-
chine.
▪ Follow all instructions.
▪ Do not perform activities for which no qualification is avail-
able. Contact properly trained personnel if necessary.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another loca-
tion can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist (see chapter 6.1 Transport,
page 28).

1D90V, 1D90W Safety
HATZ 15Operator’s Manual
3.2.2 Machine-specific safety instructions for operation
Introduction
The machine can pose residual risks during operation. To eliminate these
risks, all persons working on the machine must follow the general and ma-
chine-specific safety instructions.
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines be-
fore installing the engine.
These assembly instructions contain important information on safe installa-
tion.
If the engine is installed in a machine or assembled with other machines to
form a machine, it is prohibited to start the engine before it has been deter-
mined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations.
Safe operation
▪ Before switching on the machine, ensure that no one can be injured when
the machine is started up.
▪ During machine operation, ensure that unauthorized persons do not have
access to the area in which the machine has an impact.
▪ Parts of the exhaust gas system and the surface of the engine become hot
during operation. Risk of injury from touching hot parts! Let the engine cool
before maintenance.
▪ Do not refuel during operation.
Faults
▪ Immediately eliminate faults that compromise safety.
▪ Switch off the machine and do not take into service again until all faults
have been eliminated.
Safety instructions for operation
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.

Safety 1D90V, 1D90W
16 HATZ Operator’s Manual
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
3.2.3 Machine-specific safety instructions for maintenance work
Introduction
The machine can pose residual risks during maintenance. To eliminate
these risks, all persons working on the machine must follow the general and
machine-specific safety instructions.
Maintenance intervals
▪ Strictly adhere to the maintenance intervals.
Regular maintenance according to the instructions in this Operator's Man-
ual is essential for ensuring reliable operation and the correct engine ex-
haust quality.
▪ Check the safety equipment regularly to ensure it is in good condition and
functioning properly.
▪ Check connections, cables and fasteners regularly to ensure they are in
good condition.
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians. We recommend that you
work with one of the over 500 HATZ service stations.
Replacing parts
▪ When replacing defective components, we recommend that you use gen-
uine HATZ original spare parts (see chapter 2 General information, page
6).
▪ When disposing of parts that can no longer be used, do so in accordance
with local environmental regulations or send them to a recycling center.
Measures following maintenance and troubleshooting
▪ Securely reconnect loose electrical connections; check that the electrical
components and equipment are functioning properly.
▪ Check the entire machine for foreign bodies; remove any foreign bodies.

1D90V, 1D90W Safety
HATZ 17Operator’s Manual
Safety instructions for maintenance work
DANGER
Danger of explosion from flammable cleaning agents.
Cleaning with benzene is an explosion hazard. It is highly
flammable, can become electrostatically charged, and can gen-
erate an explosive gas/air mixture.
▪ Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
▪ Comply with manufacturer's instructions.
WARNING
Danger of injury from compressed air and dust particles.
Eye injuries may occur when cleaning with compressed air.
▪ Wear safety goggles.
CAUTION
Danger of injury if maintenance instructions are not fol-
lowed.
▪ Only perform maintenance when the engine is switched off.
▪ Protect start-up devices (crank handle, recoil start or start-
ing key) from unauthorized access.
▪ For engines with a starter: Disconnect the negative battery
terminal.
▪ When the maintenance work has been completed, ensure
that all tools are removed from the machine.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.

Safety 1D90V, 1D90W
18 HATZ Operator’s Manual
3.2.4 Electrical equipment
Safety notes
DANGER
Danger to life, danger of injury or danger of property dam-
age due to incorrect use of batteries.
▪ Do not place tools on the battery.
▪ Before performing work on the electrical equipment, always
disconnect the negative battery terminal.
▪ Never swap the positive (+) and negative (–) battery termi-
nals.
▪ When installing the battery, first connect the positive cable
and then the negative cable.
▪ When removing the battery, first disconnect the negative
cable and then the positive cable.
▪ It is imperative that you prevent short circuits and mass con-
tact of current-carrying cables.
▪ If faults occur, check the cable connections for good con-
tact.
DANGER
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪ Keep batteries away from open flames and incendiary
sparks.
▪ Do not smoke when working with batteries.
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
▪ Protect your eyes, skin, and clothing from corrosive battery
acid.
▪ Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.

1D90V, 1D90W Safety
HATZ 19Operator’s Manual
NOTICE
▪ The necessary wiring diagrams are included with the ma-
chine if it is equipped with electrical equipment. Additional
wiring diagrams can be requested when needed.
▪ We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
▪ Promptly replace faulty indicator lamps.
▪ Do not pull out the starting key during operation.
▪ Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪ When cleaning, do no spray the electrical equipment components with a
water jet or high pressure cleaner.
▪ When performing welding work on the machine, disconnect the battery
and place the ground clamp of the welding equipment as close as possible
to the welding area. Disconnect the plug-in connections to the voltage reg-
ulator.
3.3 Labels
Warning labels and information signs on the engine
Label Meaning
= 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
1D..
500h
250h
IN EX
max
OIL
DIESEL
H O
2
max
Maintenance instructions (see chap-
ter 8.1 General maintenance instruc-
tions, page 50)
Refuel with diesel fuel only. For the
specification, see chapter 4.5 Fuel,
page 26
Do not use bio diesel.
0000 053 657 02
The engine may only be operated
with fuel that is "EXTREMELY LOW
IN SULFUR OR SULFUR-FREE".
The fuel label is located close to the
fuel cap. If there is no fuel tank in-
stalled on the engine, the label must
be applied permanently close to the
fuel filler opening.

Safety 1D90V, 1D90W
20 HATZ Operator’s Manual
Label Meaning
0000 051 268 02
1 3 4
56
2
7
15s
Mechanical oil pressure shut down
device (option):
1.Engine has switched off automati-
cally.
2.Fill with fuel.
3.Make sure the engine is horizon-
tal.
4.Check the oil level.
5.Top up engine oil if required.
6.Press manual lever for approx. 15
seconds.
For engines with a fuel feed pump,
simultaneously actuate the manual
lever on the fuel feed pump sev-
eral times.
7.Start the engine.
For more information, see chapter
7.3.1 Activating the mechanical oil
pressure shut down device (option):,
page 34.