Translation of the

ORIGINAL INSTRUCTION BOOK

1D 41.
1D 42.
1D 50.
1D 81.
1D 90.

0000 433 202 09 - ENG - 12.09 - 3

Printed in Germany
33
A new HATZ diesel engine is ready to work 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 study this Instruction Book before you start the engine for the first time: it will help you to
avoid accidents, to operate the engine correctly, to perform maintenance work and to keep the engine
operating at full efficiency for a very long time.
Please pass this Instruction Manual on to the next user or to the following engine owner.

Always have service work performed by qualified specialists. To this effect, we recommend that you
consult one of the 500 HATZ service stations. There, your engine is repaired by staff who constantly
undergo training and who use both original HATZ spare parts and HATZ tools. The world-wide HATZ
service network is also available to you for consultation and spare parts supply.
For the address of your nearest HATZ service station, please refer to the attached list or the internet
under: www.hatz-diesel.com

The installation of inappropriate spare parts may cause problems. We cannnot accept any liability for
damage or consequential damage resulting therefrom.
Thus, we recommend that you use original HATZ spare parts. These parts are manufactured follow-
ing the strict HATZ specifications and ensure, thanks to their perfect fit and function, maximum oper-
ating reliability. For the reference number, please consult the attached spare part list or the internet
under: www.hatz-diesel.com. Please take the complete spare parts kits in Table M00 into account.

In the interests of technical progress we reserve the right to introduce modifications.

MOTORENFABRIK HATZ GMBH & CO KG

1
Contents

Page Page
1. Important notes on safe operation 5.3. Maintenance every 250 hours
of the engine 3 of operation 23
5.3.1. Oilbath air cleaner maintenance 23
2. Description of the engine 5
5.3.2. Changing engine oil, renewing
3. General information 7 oil filter 24
3.1. Technical data 7 5.3.3. Checking and adjusting
3.2. Transport 8 valve clearances 25
3.3 Instructions for installation 8 5.3.4. Clean the cooling air system 26
3.4. Load on engine 8 5.3.5. Checking threaded connections 27
3.5. Type plate 8 5.3.6. Cleaning mesh insert in exhaust
silencer 27
4. Operation 9
4.1. Before initial start-up 9
5.4. Maintenance every 500 hours
4.1.1. Engine oil 9
of operation 28
4.1.2. Oil bath air cleaner 9
5.4.1. Renewing fuel filter 28
4.1.3. Fuel 10
5.4.2. Dry-type air cleaner maintenance 29
4.1.4. Mechanical oil pressure monitor 11
4.2. Starting the engine 12 6. Malfunctions – Causes – Remedies 31
4.2.1. Preparations for starting 13
7. Work on the electrical system 35
4.2.2. Starting with the handle 14
4.2.3. Starting in cold weather 15 8. Protective treatment 35
4.2.4. Electric starter 16
9. Declaration for Incorporation 36
4.3. Stopping the engine 17
5. Maintenance 19
5.1. Maintenace summary 19

5.2. Maintenance every 8 – 15 hours

of operation 21
5.2.1. Check engine oil level 21
5.2.2. Check air intake point 21
5.2.3. Air cleaner blockage indicator 21
5.2.4. Checking cooling air zone 22
5.2.5. Checking the water trap 22

This symbol draws attention to important safety precautions.

Please comply with them most carefully in order to avoid any risk of injury to persons or
damage to materials.
General legal requirements or safety regulations issued by the competent authorities or
industrial accident insurers are also applicable.

2
1. Important notes on safe operation of the engine

HATZ diesel engines are economical, strongly built and long-lasting. They are therefore frequently
chosen for commercially and industrially operated equipment and machinery.
Since the engine forms part of the finished equipment or machine, its manufacturer will 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 manner in which the engine is installed and its intended application, the equipment
manufacturer or operator may have to attach additional safety devices and prohibit potentially hazard-
ous aspects of operation, for example:

– Parts of the exhaust system as well as the surface of the engine are of course hot during operation
of the engine, but also when it is still cooling down after use, and must not be touched.
– Faulty wiring or incorrect operation of electrical equipment may lead to sparks forming, and must
be avoided as a potential fire hazard.
– Rotating parts must be shielded against accidental contact when the engine is installed in other
equipment or machinery.
Guards are available from HATZ to protect belt drives, cooling fans and generators.
– Before attempting to start the engine it is essential to have studied the starting information in the
Instruction Book; this is particularly important on engines started with a starting handle.
– Mechanical starting devices must not be used by children or persons of insufficient physical
strength.
– In order to benefit from the advantages of the starting handle with kick-back damping, it must be
used precisely as recommended in this Instruction Book.
– Before starting the engine, ensure that all the specified protective guards are in place.
– The engine must only be operated, serviced or repaired by persons who have received the appro-
priate training.
– Keep the starting handle and the key out of reach of unauthorized persons.
– Never 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 (safety data sheets).

3
 Important notes on safe operation of the engine

– Stop the engine before performing any maintenance, cleaning- and repair work.
– Stop the engine before refuelling.
Never add fuel near a naked flame or a source of sparks.
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 a running engine.
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. In case a label has come off or is no longer clearly legible, it must be replaced imme-
diately. To this effect, please contact the HATZ service station in your area.
– Note that any unauthorized modification to the engine absolves its manufacturer from liability for
the consequences.
Regular servicing in accordance with the details provided in this Instruction Book is essential to keep
the engine operating reliably.

In case of doubt, always consult your nearest HATZ service station before starting the engine.

4
2. Description of engine

1D41 • 1D42 • 1D50 • 1D81 • 1D90 S / Z engines

2391 / 12 2391 / 7

1 Cooling air inlet 11 Tank filler cap

2 Dry-type air cleaner 12 Oil drain plug, governor housing
3 Decompression lever 13 Oil drain plug, governor side
4 Stop lever 14 Speed control lever
5 Cooling air outlet 15 Oil filler pipe and dipstick
6 Silencer (muffler) 16 Fuel filter
7 Guide sleeve for starting handle 17 Oil filter
8 Cylinder head cover 18 Type plate
9 Cold-start oil metering device 19 Tank drain plug
10 Suspension lug 20 Combustion air intake

5
 Description of engine

Fully-encapsulated version
1D41C • 1D42C • 1D81C • 1D90 C engines

2392 / 1 2392 / 4

1 Capsule 10 Silencer (muffler), encapsul.

2 Decompression lever 11 Cooling air outlet
3 Cold-start oil metering device 12 Battery connection and central plug
4 Combustion and cooling air intake for electrical system
5 Oil filter 13 Stop lever
6 Cleaning hatch 14 Speed control lever
7 Side panels 15 Oil drain plug
8 Hold for starting handle 16 Oil filler and dipstick
9 Suspension lug 17 Type plate

6
3. General information
3.1. Technical data
Type 1D41. 1D42. 1D50. 1D81. 1D90.
Engine models S, Z, C S, Z, C S, Z S, Z, C S, Z, C
Mode of operation air-cooled four-stroke diesel engine
Combustion method Direct-fuel injection
Number of cylinders 1 1 1 1 1
Bore / stroke mm 90 / 65 90 / 70 97 / 70 100 / 85 104 / 85
Displacement cm3 413 445 517 667 722
Engine oil content without filter 1.1 1) 1.1 1) 1.4 1) 1.8 1) 1.8 1)
approx. L
with filter 1.2 1) 1.2 1) 1.5 1) 1.9 1) 1.9 1)
Volume of oil between
„max“ and „min“ marks approx. L 0.4 1) 0.4 1) 0.5 1) 0.9 1) 0.9 1)
Consumption of lubrication oil
approx. 1 % of fuel consumption at full load
after running-in period
Engine oil pressure
Oil termperature 100 ± 20 °C min. 0.6 bar at 850 r.p.m.
Direction of rotation
looking at the flywheel counterclockwise
Valve clearance at 10 - 30 °C
Inlet 0.10 0.10 0.10 0.10 0.30
mm
Exhaust 0.20 0.20 0.20 0.20 0.30
Max. angle from vertical in any
direction (continuous operation) max. 30° 2) 30° 2) 30° 2) 25° 2) 25° 2)
Weight (incl. fuel tank, air-cleaner,
exhaust silencer and electric starter)
Engine model S approx. kg 78 78 83 105 106
Engine model Z approx. kg 81 81 85 107 108
Engine model C approx. kg 100 100 – 126 127
Battery capacity min / max 12 V - 45 / 88 Ah • 24 V - 36 / 55 Ah
Model S: non-encapsulated, normal system of balancing
Z: non-encapsulated, add. system of balancing
C: SILENT PACK, add. system of balancing
1) These data are approx.-values. The max. mark on oil dipstick counts.
2) Exceeding these limits causes engine breakdown.

7
3.2. Transport 3.4. Load on engine
A lug is provided on top of the engine Operating the engine for a lengthy period off-
as standard equipment, so that the en- load or at very low loads can affect its running
gine can be lifted safely. It is not suitable for quality.
lifting complete machines or similar with the We therefore recommend a minimum engine
engine attached, and this is strictly prohibited. load of 15 %. If operated at such low loads, it is
(See Chapter 2.) best to operate the engine at a significantly high-
er load for a short period before switching it off.

3.3. Instructions for installation

The „Manual for Selection and Installation of En- 3.5. Type plate
gines“ contains all the information you need if
your engine has not yet been installed on or in
the equipment it is intended to drive, or set up
in its correct operating position. You can obtain
a copy of this manual from your nearest HATZ
service station. ➀ ➁
Moreover, we would like to point out that in this
➂
case, commissioning is prohibited until it has
been verified that the machine into which this ➃
engine is to be incorporated complies with the
regulations of the EC Machinery Directive.
Refer also to Chapter 9 „Declaration for Incorpo-
ration“.

4
START
The type plate is placed on the crankcase resp.
F<
– 10 N
on the capsule (chapt. 2) and includes the fol-
lowing engine information:
M<
– 0.35 Nm ➀ engine type
STOP
➁ code (only for special equipment)
F< ➂ engine number
– 120 N
➃ max. engine speed
M<
– 12.6 Nm
+ 70° For any offer as well as spare parts orders it is
necessary to mention these data (also see spare
parts list, page 1).

The permitted loads and elements on

the speed adjusting lever and the stop
lever should be observed as an exess can lead
to damage to the contacts and inner governor
parts.
8
 The engine must be in a horizontal position be-
4. Operation fore adding oil or checking the oil level.
4.1. Before initial start-up
Engines are normally delivered without fuel and
oil.

4.1.1. Engine oil

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.
1
If engine oil of a poorer quality is used, reduce
oil change intervals to 150 hours of operation. 6

Oil viscosity – Pull out dipstick „1“ and add engine oil of the
correct specification and viscosity up to the
°F °C OIL: SAE...
„max“ mark on the dipstick; (Chapter 3.1.).
122 50

104 40

86 30 4.1.2. Oil bath air cleaner

10W/40
15W/40

40
5W/40

10W/30

30
5W/30

68 20

50 10
10W

32 0

14 -10
2
-4 -20

-22 -30

-40 -40

Please select the recommended viscosity de-

pending on the ambient temperature at which
the engine is operated. 3 1
2393 / 6

7
Inappropriate engine oil may shorten the
engine’s service life significantly. – Take off the oil reservoir and fill it up to the
mark „1“ using engine oil.
– Attach the oil reservoir, making sure that seal-
ing ring „2“ is correctly seated and catches „3“
are tight.

9
4.1.3. Fuel
Only refuel when engine is stopped.
Never refuel close to open flames or
flammable sparks, don’t smoke. Use only pure
fuel and clean replenishing cups. Don’t spill
the fuel.

All diesel fuels sold as fuel and complying with

the following minimum specification can be
used:

EN 590 or
BS 2869 A1 / A2 or 2287 / 11
ASTM D 975 - 1D / 2D 9

Important ! – If the fuel tank is not mounted on top of the

The use of fuels of different specifications re- engine, or is at a lower level, operate the lever
quires the prior written consent of the HATZ on the fuel feed pump until fuel is heard to
headquarters. flow back to the tank through the return line.

2286 / 2
2292 / 4
8
10
– Before the first start or if the fuel tank has
– On fully encapsulated engines, move sleeve
been run dry, completely fill the fuel tank with
„1“ to one side to gain access to the feed
diesel.
pump.
The fuel system is bled automatically if the
After operating the feed pump, make sure that
fuel tank is attached to the engine or located
the sleeve is replaced correctly and makes a
higher than the injection pump.
good seal.

10
At temperatures below 0 °C, winter-grade fuel
should be used or parafin added to the fuel well
in advance.

Lowest ambient Paraffin content for:

temperature when Summer Winter
starting, in °C fuel fuel
0 up to –10 20 % – 1
–10 up to –15 30 % –
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %

4.1.4. Mechanical oil pressure 11

monitor (optional extra)
– To activate the monitor, press lever „1“ for
The mechanical oil pressure monitor should be approx. 15 seconds.
activated:
• when first filling, or after running the fuel tank
dry.
• if engine shut down automatically because lu-
bricating oil supply was inadequate.
• after freeing it by turning at low temperatures
(Chapter 4.2.4.)
• after replacing the fuel filter, Chapter 5.4.1.

– Add fuel, chap. 4.1.3.

1
– Check engine oil level, chap. 5.2.1.
2392 / 12

12

– If the engine has a full capsule, press pin „1“

for app. 15 seconds.
– If the engine has a fuel feed pump, operate its
lever for several strokes at the same time
(Figs. 9 and 10).
– Re-assemble all parts repositioned or re-
moved. Check that capsule elements make a
good seal.

11
 0000 053 755 00
1 2 3 4

5 6 7

15s
0000 051 268 02

13 14

Instructions to activate the mechanical oil pres- Do not enter the guide sleeve of
sure control are mentioned on the sticker placed the starting device whilst engine
on the engine. is running - risk of injury !

IMPORTANT !
Even with mechanical oil pressure monitoring
the oil level must be checked every 8 – 15
operating hours (Chapter 5.2.1.).

4.2. Starting the engine

Do not run the engine in closed or
badly ventilated rooms – danger of
poisoning ! Before the engine is started, al-
ways make sure that nobody is in the danger 050 145 00

area (moving parts on engine or machinery)

and that all safety guards are in place. L3 / 250

15
Check that the starting handle is in good condi-
tion: renew tubular grip if broken, worn drive pin
etc. Never use any spray starting aids.
Lightly grease the sliding-contact area between
the starting handle and the guide sleeve.

12
4.2.1. Preparations for starting
– If possible, disengage the engine from any
driven equipment. The auxiliary equipment
should always be placed in neutral.

START

STOP 1 0
2
START
2292 / 6

1 18

– Turn the decompression lever until stop „1“ is

STOP reached. In this position the automatic decom-
pression system is heard to engage and the
2396 / 3
engine can then be started; Figs. 17 and 18.
16

– Set speed control lever „1“ to a position be- 1

tween 1/2 START and max. START, according
2
to requirements. Selecting a lower engine
speed will reduce smoke when starting.
– Make sure that stop lever „2“ - if fitted - is in
the operating „START“ position.
3
2

1
5x

19

After the automatic decompression device has

engaged at its limit stop, five turns of the crank
0 handle are needed for the engine to build up
compression and fire again.

2283 / 4

17

13
4.2.2. Starting with the handle – Turn the handle slowly until the pawl engages
in the ratchet, then increase turning force to
For preparations to start the engine, build up speed. The highest speed must have
see Chapter 4.2.1. been reached when the decompression lever
returns to the „0“ position (compression). As
soon as the engine has started, pull the start-
ing handle out of the guide sleeve.
You must hold the tubular grip firmly to
maintain contact all the time between
the starting handle and the engine. Maintain
turning force during the entire hand starting
operation.

If backfiring occurs when starting the engine be-

cause the crank handle was not turned firmly
enough, the brief reverse rotation at the handle
tube separates the link between crank lug „2“
and driving dog „3“ (Fig. 21).
20
– If the engine begins to run backwards after
For correct position to adopt when starting the backfiring (smoke emerges from air cleaner),
engine, see Fig. 20. release the crank handle immediately and stop
the engine (Chapter 4.3.).
Starting with the handle with kick-back – To restart the engine, wait until it has come to
damping (retrofit) a standstill, then repeat the starting prepara-
tions.

3 Starting by means of the standard

starting crank
In the countries of the European Union,
starting cranks without kick-back dam-
ping must not be used.

For preparations to start the engine,

2 1
see Chapter 4.2.1.

2395 / 4
– For correct position to adopt when starting the
engine, see Fig. 20.
21

– Always hold tubular grip „1“ with both hands.

14
– Take hold of the starting handle with both
hands and turn it at increasing speed. The
maximum speed of rotation must have been
reached by the time the decompression lever
has returned to the „0“ position (compres-
sion). As soon as the engine has started, pull
the starting handle out of the guide sleeve.
– If the engine backfires because the crank han-
dle was not turned firmly enough (the engine
may even start to run backwards), release the
crank handle immediately and stop the engine
(Chapter 4.3.).
2283 / 8
There is a risk of injury from the
rotating crank handle. 22

– To restart the engine, wait until it has come to

a standstill, then repeat the starting prepara-
tions.
Safety precaution
For greater protection against accidental injury
when starting with the handle, a handle with
kick-back damping can be used.

4.2.3. Starting in cold weather

At temperatures below app. –5 °C, always turn
the engine over to ensure that it rotates freely. 2392 / 9

23
– Move the speed control lever to the START
position; Fig. 16. – Remove dirt from the cover of the metering
device and the surrounding area. Pull off the
– Place decompression lever in central position
cover; Figs. 22 and 23.
between „0“ and „1“ (Fig. 17 and 18).
– Add a free-flowing lubricating oil to the
– Turn the engine over with the starting handle
housing until the level reaches the upper rim.
until it is felt to rotate more freely (10 – 20
Replace the cover and press it in firmly. Two
turns of the starting handle).
filling operations in succession are needed.
– If mechanical oil pressure monitoring is
– Turn the decompression lever until
fitted, press lever „1“ or pin „1“ in for about
limit stop „1“ (fig. 17 and 18).
15 seconds (Figs. 11 and 12).
– After this, start the engine immediately.
Chap. 4.2.1. / 4.2.2.

15
4.2.4. Electric starter – Always turn the start key back to position 0
before re-starting the engine. The repeat lock
For preparations to start, see Chapter 4.2.1. in the ignition lock prevents the starter motor
from engaging and possibly being damaged
– The decompression lever remains in pos. „0“. while the engine is still running.
Never operate the electric starter when
Starting procedure the engine is running or coasting to a
standstill. There is a risk of broken starter pin-
ion or ring gear teeth.
1
Important:
2 If a start protection module is installed, the start
key has to be returned to position 0 for at least
3 8 seconds if the engine has failed to start before
a further attempt to start the engine can be
4 made.

Preheating device with automatic

5 heating timer (additional equipment)
The preheating light „5“ lights up additionally at
24
temperatures below 0° Celsius (Fig. 24).
– Insert the key to its stop and turn it to
– After the light has gone out, start the engine
position I.
without delay.
– Battery charge telltale „2“ and oil pressure
warning „3“ must light up.
– Turn start key to position II (fig. 24).
– As soon as the engine runs, release the start
key. It must return to position I by itself and
remain in this position during operation.
The battery charge telltale and oil pressure
warning must go out immediately after start-
ing. Indicator light „1“ is on when the engine
is in operation.
– If anything seems to be incorrect, stop the en-
gine immediately and trace and rectify the fault
(chapt. 6).
– 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 elimi-
nate the cause of the problem, chap. 6.

16
Automatic electrical shutdown system 4.3. Stopping the engine
(additional equipment) Never stop the engine by moving the
This is characterized by a brief flashing of all decompression lever. During breaks
pilot lamps once the starter key has been turned in work or at the conclusion of the working pe-
to position I (Fig. 24). riod, keep the starting handle and starting key
in a safe place, out of reach of unauthorized
Important ! persons.
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. 24, positions 2 - 4) will come on.
After the engine has stopped, the display con-
tinues to glow for about 2 minutes.

0000 050 616 01

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).

The display light goes out when the engine is 25

next started. Never stop the engine by actuating the
Even with automatic shutdown monitoring the decompression lever !
oil level must be checked every 8 – 15 operat- Risk of damage to the engine.
ing hours (Chapter 5.2.1.).

START

STOP
2
START

STOP

2396 / 3

26

– Move speed control lever „1“ back to the

STOP position.

17
– On engines with the lower engine speeds Electrical system
not accessible, move speed control lever „1“
back, then move stop lever „2“ in the STOP
direction. Hold it there until the engine has
stopped.
1
– Once the engine is not running any longer, 2
release the stop lever.
The stop lever is returned automatically to its 3
operating position START via a spring.
4

5
27

The charge „2“ and oil pressure telltales „3“

come on.

– Turn the key to the 0 position and pull it out.

The telltale lights must then go out.

Note:
Engines with an automatic electrical shutdown
system (Chapter. 4.2.4.) can also be switched
off by turning the start key back to position 0.

18
5. Maintenance
The engine must be stopped before any maintenance work is attempted.
Comply with legal requirements when handling and disposing of old oil, filters and
cleaning materials.
Keep the engine’s starting key and starting handle out of reach of unauthorized persons.
To immobilize engines with an electric starter, disconnect the negative battery terminal.
At the end of the maintenance work, check that all tools have been removed from the engine and
all safety guards, covers etc. replaced in their correct positions.
Before starting the engine, make sure that nobody is in the danger area (engine or driven
machinery).

5.1. Maintenance summary

Maintenace intervals Maintenance work required Chap.

Check oil level. 5.2.1.

Check area round combustion air input. 5.2.2.
Check the air cleaner maintenance indicator. 5.2.3.
Every 8 – 15 operating Check the cooling air zone. 5.2.4.
8-15 hours or before daily Check the water trap. 5.2.5.
starting. Check the lower part of the oilbath air cleaner for
correct oil level and freedom from dirt; renew oil if 4.1.2.
sludge has formed. 5.3.1.

Maintenance of oil bath air filter. 5.3.1.

Replace engine oil and oil filter. 5.3.2.
Every 250 operating Check and adjust tappet clearance. 5.3.3.
250 5.3.4.
hours Clean cooling air system.
Examine screw connections. 5.3.5.
Cleaning mesh insert in exhaust silencer 5.3.6.

Every 500 operating- Replace fuel filter. 5.4.1.

500 hours Maintenance of dry-air filter. 5.4.2

19
28

The above maintenance chart is supplied with For new or reconditioned engines, the following
every engine. This label should be affixed to the must always be carried out after first 25 operat-
engine or equipment in an easily visible position. ing hours:
The maintenance chart governs the maintenance
intervals. – Replace engine oil and oil filter, chap. 5.3.2.
– Check tappet clearance, and adjust if neces-
sary, chap. 5.3.3.
– Examine screw connections, chap. 5.3.5.
Do not tighten the cylinder head fastening.

For short operating periods: replace engine oil

and oil filter after 12 months at the latest, re-
gardless of the number of operating hours.

20
5.2. Maintenance every 8 – 15
hours of operation
5.2.1. Check engine oil level
When checking the oil level, the engine should
be standing level, and must not be running.

– Remove any dirt in the dipstick area. 1

2393 / 10

30

– Check that dust outlet „1“ on the centrifugal

dust trap (depending on version) is not
blocked, and clean if necessary.

5.2.3. Air cleaner blockage indicator

(optional extra)
– Run the engine at full speed shortly.
29

– Check oil level at the dipstick; top up if neces-

sary as far as the „max“ mark
(see Chapter 4.1.1.).

5.2.2. Check air intake point

Severe contamination is a sign that there are
large amounts of dust in the atmosphere and
the air cleaner maintenance intervals should be 1
reduced.

– Depending on the air intake pattern, check for

severe blockage; clean if necessary 2391 / 10
(see Chapter 2).
31

If the rubber bellows is pulled in and obscures

the green zone „1“, maintenance work is due on
the air cleaner; Chapt. 5.4.2. In dusty operating
conditions, check the rubber bellows several
times a day.

21
5.2.4. Checking cooling air zone – Trap the drops which emerge in a transparent
vessel. Since water has a greater specific
Severe contamination is a sign that there are gravity than diesel fuel, the water emerges be-
large amounts of dust in the atmosphere and fore the diesel fuel. The two substances sepa-
that maintenance intervals should be reduced. rate at a clearly visible line.
– As soon as diesel only emerges at screw „1“,
– Check the air inlet and outlet zones for block- this can be tightened again.
age by coarse material such as leaves, large
amounts of dust etc., and clean if necessary If an external water trap is attached, check its
(see chapters 2 and 5.3.4.). water content every day, when the engine oil
level is checked. The water which has collected
– If a temperature warning light „4“ is provided, is separated at a clearly visible line from the
it will come on if the engine overheats, fig. 27. diesel fuel above it.
In this case, stop the engine immediately
(Chapter 4.3. and 5.3.4.).

5.2.5. 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 re-
fuelling. The normal interval is once a week.

1
2396 / 9

33

– Open drain plug „1“ and drain the water out

into a suitable vessel.
1 – If the drain plug is difficult to reach, an exten-
sion hose can be attached to it.

2396 / 7

32

– Loosen hexagon screw „1“ with approx. 2-3

rotations.

22
5.3. Maintenance every 250 – If the sealing face is uneven, the air cleaner
body cracked and/or the filter wool content is
hours of operation
incomplete, install a new air cleaner.
5.3.1. Oil bath air cleaner maintenance – Attach the upper part of the air cleaner with a
new flange gasket.

2395 / 13

34

Catch waste oil and dispase acc. to

environmental regulations. 35

– Sealing package acc. picture 35 is mounted at

– Take off the oil reservoir „1“ and clean it.
engines 1D41, 1D42 and 1D50.
– Remove contaminated oil and sludge from the
oil tank, and clean it out.
– Take off rain cap „2“ and clean it.
– Clean the entire length of intake pipe „3“.
– Check the inserted seal and renew if in poor 1
condition.
– Fill the oil reservoir up to the mark with engine
oil and re-assemble the oilbath air cleaner,
Chap. 4.1.2.
– If the filter pack is very dirty, also clean the
upper part of the air cleaner as follows:
Remove the upper part of the air cleaner from
the engine and rinse it in diesel oil.
36
– Before re-assembling the air cleaner, allow the
diesel fuel to drip off thoroughly, or wipe it off. – Shim washers „1“ should be installed with the
convex side (outward curve) towards the nut.
– Never attempt any repairs (welding, brazing
etc.) to the oilbath air cleaner, or it may be – Re-assemble the complete air cleaner and fill it
rendered useless and the engine may also be with oil to make it ready for further operation.
damaged.

23
5.3.2. Changing engine oil, Fully encapsulated engines:
renewing oil filter
The engine must be stopped, and should stand
on a flat, level surface.
Drain the engine oil only when it is warm.
For oil drain plug, see Chapter 2.

Risk of scalding from hot oil.

Catch waste oil and dispase acc. to 1
environmental regulations.

2292 / 9

38

When unscrewing oil drain plug „1“, make sure

that the drain tube is not loosened. Prevent it
from turning if necessary with an open-ended
wrench of the correct size.

– Clean the oil drain plug and attach a new seal.

Insert and tighten the plug.

37

– Unscrew the oil drain plug and allow all the oil
to drain out.

1
2287 / 13

39

– Renew the replaceable lubricating oil filter ele-

ment.

24
 5.3.3. Checking and adjusting
valve clearances
– Move the decompression lever to
position „0“; Fig. 17 and 18.

3
2
40

– Clean sieve bottom carefully in order not to

bend the netting. 1
Wipe out cap screw or blow it out with com-
pressed air.
Persons handling compressed air must 41
wear protective goggles. Never direct
the jet at animals, persons or yourself ! – In case of the enclosed design, please remove
the parts of the enclosure in the order 1...4.
The decompression lever is also taken off
Important ! when the cover is removed.
Note the „TOP“ mark on the oil filter. Fig. 39

– Check condition of O-ring „1“ and renew it if

necessary (Fig. 39).
– Wet the thread and the O-ring of the screw
plug with lubricant „K“ (see spare parts list). 1
– Add engine oil up to the „MAX“ mark on the
dipstick (see Chapter 4.1.1.) 2

– Run the engine for a short period, then check

the oil level again and top up if necessary. 0
– Check that there is no leakage past screw plug
on the oil filter housing.
2393 / 15

42

– Unscrew cover „1“ and take off together with

gasket „2“. Never re-use this gasket.

25
– Turn the engine over in the normal direction of
rotation until compression is felt.

1
3
1
3

44
2 – In case of the enclosed design, place the lever
for decompression „1“ in horizontal position.
43 Then, mount the cover of the enclosure in the
order 2...3.
– Check valve clearances between rocker and
valve stem, using feeler gauge „1“. For the – After a short test run, check the cylinder head
setting, refer to Chapter 3.1. cover for leakage.
– If valve clearance is incorrect, slacken off hex.
nut „2“.
5.3.4. Clean the cooling air system
– Turn adjusting screw „3“ with a screwdriver
until feeler gauge „1” can just be pulled Before cleaning, the engine must be
through between the rocker and the valve stopped and allowed to cool down.
stem with slight resistance to its movement
after nut „2“ has been retightened. Remove parts of air duct.

– Attach the cover at the cylinder head again and Dry contamination
tighten down uniformly. – Clean all air guide elements and the complete
cooling air zones on the cylinder head, cylin-
– Depending on version mount parts of air duct. der and flywheel blades without making them
wet. Blow them dry with compressed air.
Persons handling compressed air must
wear protective goggles. Never direct
the jet to animals, persons or yourself !

26
Moist or oily contamination
– Disconnect the battery. Clean the complete
area with a solvent, cold cleaner etc. according
to its manufacturer’s instructions, then spray
down with a powerful water jet.
Do not splash electrical device with water jet
or pressure jet during engine cleaning.
Important !
When cleaning the engine, do not direct a
jet of water or a high-pressure jet at the
components of the electrical equipment.

2396 / 3
– Trace the cause of any contamination with oil
and have the leak eliminated by a HATZ 45
service station.
Adjustment screws on speed governor
– Install the air guide elements previously re- and injection system are painted with
moved. safty lacquer. Do not tighten or adjust them.
The engine must never be run without
the air guide elements in position.
5.3.6. Cleaning mesh insert in exhaust
– Immediately after re-assembly, run the engine
silencer (additional equipment)
until warm to prevent residual moisture from
causing rust.

5.3.5. Checking threaded connections

Check the condition and tightness of all threaded
connections, wiring, hose clips and other com-
ponents attached to the engine and its mount-
ings, provided that these can be reached during
maintenance work.
Do not tighten the cylinder head bolts.

46

– Remove deposits from the mesh insert with a

suitable wire brush.

27
5.4. Maintenance every 500
hours of operation
5.4.1. Renewing fuel filter
Fuel filter maintenance intervals depend on the
purity of the fuel used; reduce them to 250
hours of operation if necessary.

Do not smoke or bring a naked flame

near the fuel system when working
on it.

Important !
Keep the entire area clean so that no dirt
48
reaches the fuel. Fuel particles may damage
the injection system. – Unscrew the fuel filter from its mount.

1
1

2
47
49
– Shut off the fuel supply line upstream and
– Place a suitable vessel under the filter to trap
downstream of the fuel filter according to
escaping fuel.
item 1.
– Pull off fuel supply line „1“ at both ends of fuel
filter „2“ and insert the new filter.
– Always renew the fuel filter. Note the arrows
indicating the correct direction of fuel flow.
– Secure the filter to its mount.
– Open the fuel supply line or prime the pump
until the fuel flows (see Chapter 4.1.3.).

28
– Activate mechanical oil pressure monitor
(optional extra), chap. 4.1.4.
– Run the engine briefly to check the fuel filter
and lines for leaks.

5.4.2. Dry-type air cleaner maintenance 2

1
It is best to clean the filter cartridge only when
the maintenance indicator displays the appropri-
ate signal.
Apart from this, the cartridge should be renewed
after 500 hours of operation. 2396 / 16

51

– Slacken off wing bolt „1“ and remove it with

cover „2“.
2

1 1

50
2 4
– In case of the enclosed design, please remove
the cover of the enclosure in the order 1...2.
The decompression lever is also taken off 2393 / 1

when the cover is removed. 52

– Carefully pull out filter cartridge „1“.

– On the version with air cleaner maintenance
indicator, check that valve plate „4“ is clean
and in good condition.
– Clean filter housing and cover.
Make sure that dirt or other foreign matter
cannot enter the engine air intake port.

29
Cleaning the filter cartridge
Dry contamination

3
1

54
2281 / 5 – In case of the enclosed design, place the lever
53 for decompression „1“ in horizontal position.
Then, mount the cover of the enclosure in the
– Blow through the filter cartridge from the in- order 2...3.
side, moving the jet of dry compressed air up
and down until no further dust is expelled.
Warning: air pressure must not exceed 5 bar.
Persons handling compressed air must
wear protective goggles. Never direct
the jet to animals, persons or yourself !

– Tilt the filter element and hold it against the

light (or shine a light through it) to trace any
cracks or other damage.
Important:
If there is even the slightest damage to paper
filter element „2“ or sealing lips „3“, the filter
element should not be re-used. (Fig. 52)

Wet or oily contamination

– Renew the filter cartridge.
– Re-assemble in the reverse order of work.

30
6. Malfunctions – Causes – Remedies

Malfunction Possible causes Remedial action Chap.

Engine will not Speed control lever is in stop or

start or start is idle position.
delayed, although Stop lever in stop position. Set lever to „START“-position 4.2.
it can be turned
over with the No fuel reaching injection pump. Add. fuel. 4.1.3.
starter. 4.1.4.
Check entire fuel supply system
carefully.
If no fault is found:
- supply line to engine
- fuel filter 5.4.1.
- Function of delivery pump
must be checked. 4.1.3.
Compression too low:
- Valve clearances incorrect Check valve clearances, adjust if
necessary. 5.3.3.
- Cylinder bore and/or piston
ring wear See workshop manual.

Injector not operating correctly. See workshop manual.

Also applicable for Oil pressure lost. Check engine oil level. 5.2.1.
engines with me-
chanical oil pres- Activate mechanical oil pressure
sure monitoring. monitor. 4.1.4

At low tempera- Lower starting temperature limit Comply with cold starting
tures. exceeded. instructions. 4.2.3.
Operate preheat system
(optional extra). 4.2.4.

Machinery not uncoupled. Disengage engine from machin-

ery or equipment if possible.

Defective preheat system

(optional extra). See workshop manual.

31
Malfunction Possible causes Remedial action Chap.

At low Fuel separates has inadequate Check whether clear (not turbid)
temperatures. resistance to low temperatures. fuel emerges at the fuel line de-
tached from the injection pump.
If turbid or separated - either
warm up the engine or drain the
complete fuel supply system.
Refuel with winter-grade fuel to
which paraffin has been added. 4.1.3.
Starting speed too low:
- Engine oil is too thick Refill with a different grade of
engine oil. 5.3.2.

- Battery charge is insufficient. Check the battery; consult a spe-

cialist workshop if necessary. 7.

Starter does not Fault in electrical system:

run or engine is - Battery and/or other wiring is Check electrical system incl.
not turned over. wrongly connected. indiv. components or contact a
- Wiring connections loose HATZ-service station. 7.
and/or corroded.
- Battery defective and/or flat.
- Defective starter motor
- Defective relays, monitoring
elements etc.

Engine fires but Drive still engaged. Uncouple engine from driven
stops again as machinery if possible.
soon as starter is Fuel filter blocked. Renew the fuel filter. 5.4.1.
switched off.
Fuel supply interrupted. Check through the entire fuel
supply systematically.
Stop signal from monitoring
element for automatic shutdown
system (optional extra):
- oil pressure lost Check oil level. 5.2.1.
- cylinder head temperature
too high. Clean cooling air system. 5.3.4.

- alternator has failed See workshop manual.

32
Malfunction Possible causes Remedial action Chap.

Engine stops by Fuel supply is interrupted:

itself during re- - Tank run dry Add fuel. 4.1.3.
gular operation. 4.1.4.
- Fuel filter blocked Renew fuel filter. 5.4.1.
- Defective feed pump. Check through entire fuel supply
system.
- Air in the fuel system. Check fuel system for
penetration of air.
Check air vent valve.

Mechanical oil pressure monitor Check engine oil level. 5.2.1.

stops the engine due to low oil Activate mechanical oil pressure
pressure. monitor. 4.1.4.

Mechanical defects. Contact a HATZ-service station.

In addition, if auto- Stop signal from monitoring

matic engine shut- element because of: Check engine for:
down is installed. - oil pressure too low. Engine oil level.
- cylinder head temperature Cooling air passages blocked
too high. or cooling system otherwise
affected.
- alternator has failed See workshop manual.

Malfunction signal from over-

voltage and polarity reversal
protection in voltage regulator:
- Battery and/or other cable
connections incorrectly con-
nected. Check electrical equipment and
- Cable connections loose. the components thereof.

33
Malfunction Possible causes Remedial action Chap.

Low engine power, Fuel supply is obstructed:

output and speed. - Tank run dry. Add fuel. 4.1.3.
4.1.4.
- Fuel filter blocked. Renew fuel filter. 5.4.1.

- Tank venting is inadequate Ensure that tank is adequately

vented.
- Leaks at pipe unions. Check threaded pipe unions for
leaks.
- Air in the fuel system. Check fuel system for
penetration of air.
Check air vent valve.

- Speed control lever does not Prevent speed control from

remain in selected position. moving.

Low engine power, Air cleaner blocked. Remove dirt from air cleaner. 5.3.1.
output and speed, 5.4.2.
black exhaust Incorrect valve clearances. Adjust valve clearances. 5.3.3.
smoke. Malfunction at injector. See workshop manual.

Engine runs very Too much oil in engine. Drain off engine oil down to
hot. Cylinder head upper mark on dipstick. 5.3.2.
overheat, telltale Inadequate cooling:
lamp (optional - Entire cooling air system Clean cooling air system. 5.3.4.
extra) comes on. contaminated.
- Inadequate sealing at air guide Check that air guide plates and
plates or capsule elements. enclosure elements are all pres-
ent and make a tight seal.

34
 – Do not splash electrical device with water jet
7. Work on the electrical system or pressure jet during engine cleaning.
Batteries generate explosive gases. – When carrying out welding work on the en-
Keep them away from naked flame gine or attached equipment, attach the earth
and sparks which could cause them to ignite. (ground) clip as near as possible to the weld-
Do not smoke. Protect the eyes, skin and ing point, and disconnect the battery.
clothing against battery acid. Pour clear water If an alternator is fitted, separate the plug con-
over acid splashes immediately. In case of nector leading to the voltage regulator.
emergency call doctor.
The relevant circuit diagrams are supplied with
Do not place any tools on top of the battery.
engines which have an electrical system.
Additional copies of circuit diagrams can be
Always disconnect the negative (–) pole of the
obtained on request.
battery before working on the electric device.
HATZ assumes no liability for electrical systems
– The positive (+) and negative (–) battery ter-
which was not carried out acc. HATZ circuit dia-
minals must not be accidentally interchanged.
grams.
– When installing the battery, connect the posi-
tive lead first, followed by the negative lead.
Negative pole to earth (ground) on engine
block. 8. Protective treatment
– When removing the battery, disconnect the
negative lead first, followed by the positive A new engine can normally be stored for up to
lead. 12 months in a dry place.
– In all circumstances, avoid short circuits and If atmospheric humidity is high (or if exposed
shorts to earth (ground) at live cables. to sea air), protection is sufficient for about
6 months’ storage.
– If electrical faults occur, first check for good If the engine is to be stored for a longer period,
contact at the cable connections. or laid up out of use, please consult the nearest
– Replace a failed indicator light without delay. HATZ service point.

– Do not take the key out while the engine is

running.
– Never disconnect the battery while the engine
is running. Electric voltage peaks can cause
damage to electrical components.
– In case of an emergency start in manual
mode, leave the battery (which might be dis-
charged) connected to the engine.
– For emergency operation without battery,
make sure that the plug-and-socket connector
to the instrument box is disconnected addi-
tionally before the engine is started.

35
36
 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.