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!