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Hatz Diesel 1D90V, Original Instruction Book

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Hatz Diesel 1D90V Original Instruction Book Download Page 1

1D90V | 1D90W

www.HATZ-DIESEL.com

Hatz Diesel

CREATING POWER SOLUTIONS.

Translation of the

ORIGINAL

INSTRUCTION BOOK

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Summary of Contents for 1D90V

Page 1: ...A AN NU UA AL L F FO OR R M MO OD DE EL L Y YE EA AR R 2 20 01 15 5 E EP PA A C CE ER RT TI IF FI IE ED D N NO ON NR RO OA AD D C CO OM MP PR RE ES SS SI IO ON N I IG GN NI IT TI IO ON N E EN NG GI IN NE ES S I IN NC CL LU UD DE ES S S SU UP PP PL LE EM ME EN NT TA AL L I IN NF FO OR RM MA AT TI IO ON N F FO OR R T TH HE E U US SE E O OF F E EP PA A C CE ER RT TI IF FI IE ED D E EN NG GI IN NE ES ...

Page 2: ... 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 pa...

Page 3: ...ntenance every 250 hours of operation 19 5 3 1 Changing engine oil renewing oil filter 19 5 3 2 Checking and adjusting valve clearances 20 5 3 3 Clean the cooling air system 21 5 3 4 Checking threaded connections 21 5 4 Maintenance every 500 hours of operation 22 5 4 1 Renewing fuel filter 22 5 4 2 Dry type air cleaner maintenance 22 6 Malfunctions Causes Remedies 24 7 Work on the electrical syste...

Page 4: ...r 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 en...

Page 5: ... 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 liabili...

Page 6: ...air cleaner 6 Tank drain plug 7 Cylinder head cover 8 Tank filler cap 9 Cooling air inlet 10 Air cleaner maintenance indicator 11 Speed control lever 12 Oil filter optional extra 13 Fuel filter 14 Cooling air outlet 15 Silencer muffler 16 Starter motor 17 Central plug for electical system 18 Oil drain plug ...

Page 7: ...pressure Oil temperature 100 20 C min 0 6 bar at 850 r p m Direction of rotation looking at the flywheel counterclockwise Valve clearances at 10 30 C Inlet mm 0 30 Exhaust mm 0 30 Max angle from vertical in any direction continuous operation max 25 2 Weight incl fuel tank air cleaner exhaust silencer and electric starter Engine models V approx kg 106 Engine models W approx kg 108 Battery capacity ...

Page 8: ...ngines These instructions are available from the HATZ service center in your area Pending complete installation the engine must not be started Moreover we would like to point out that in this case commissioning of the machine is also pro hibited until it has been verified that the machine into which this engine is to be incorporated complies with all the safety precautions and reg ulations provide...

Page 9: ...e original type plate on the engine is not readily visible after the engine is installed in the equipment then the second loose type plate must be attached on the equipment in such a manner that it is readily visible to an average person For any offer as well as spare parts orders it is necessary to mention the following data also see spare parts list page 1 engine type spec only for special equip...

Page 10: ...nding on the ambient temperature at which the engine is operated Inappropriate engine oil may shorten the engine s service life significantly The engine must be in a horizontal position be fore adding oil or checking the oil level 6 Remove oil fill screw 1 and dipstick 2 Add engine oil up to the max mark on the dipstick Lubricating oil capacity see Chapter 3 1 Tighten oil fill screw by hand Attent...

Page 11: ...s 7 Add diesel fuel to the fuel tank until it is at leasthalf full The fuel system is bled automatically if the fuel tank is attached to the engine or located higher than the injection pump 8 If the fuel tank is not mounted on top of the engine or is at a lower level operate the lever on the fuel feed pump until fuel is heard to flow back to the tank through the return line At temperatures below 0...

Page 12: ... 1 2 Check engine oil level chap 5 2 1 9 To activate the monitor press lever 1 for approx 15 seconds If the engine has a fuel feed pump operate its lever for several strokes at the same time Fig 8 10 Instructions to activate the mechanical oil pres sure control are mentioned on the sticker placed on the engine IMPORTANT Even with mechanical oil pressure monitoring the oil level must be checked eve...

Page 13: ...ids 4 2 1 Preparations for starting If possible disengage the engine from any driven equipment The auxiliary equipment should always be placed in neutral 12 Set speed control lever 1 to a position be tween 1 2 START and max START according 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 4 2 2 El...

Page 14: ...o position 0 for at least 8 seconds after the engine has failed to start or after switching it off before a further at tempt can be made to start the engine Preheating device with automatic heating timer additional equipment The preheating light 5 lights up additionally at temperatures below 0 Celsius Fig 13 After the light has gone out start the engine without delay Automatic shut down function a...

Page 15: ... lever 2 optional extra in the STOP direction Hold it there until the engine has stopped Once the engine is not running any longer release the stop lever The stop lever is re turned automatically to its operating position START via a spring 15 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 a...

Page 16: ...tarting 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 Every 8 15 operating hours or before daily starting Check oil level Check area round combustion air input Check the air cleaner maintenance indicator Check the cooling air zone Check the water trap 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 Every ...

Page 17: ...rs Replace engine oil and oil filter chap 5 3 1 Check tappet clearance and adjust if neces sary chap 5 3 2 Examine screw connections chap 5 3 4 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 16 IN EX 1h 1D41 1D42 1D50 1D81 1D90 IN 0 1 mm IN 0 1 mm IN 0 1 mm IN 0 1 mm...

Page 18: ...rated while the oil level is below the min mark or above the max mark it can cause damage to the engine 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 re duced Depending on the air intake pattern check for severe blockage clean if necessary see Chapter 2 5 2 3 Air cleaner blockag...

Page 19: ...e amount of water in the fuel and the care taken when re fuelling The normal interval is once a week 19 Loosen hexagon screw 1 with approx 2 3 rotations Trap the drops which emerge in a transparent vessel Since water has a greater specific grav ity than diesel fuel the water emerges before the diesel fuel The two substances separate at a clearly visible line As soon as diesel only emerges at screw...

Page 20: ...d allow all the oil to drain out Clean the oil drain plug and attach a new seal 2 Insert and tighten the plug 22 Renew the replaceable lubricating oil filter element optional extra Catch leaking oil Important Note the TOP mark on the oil filter 23 Clean sieve bottom carefully in order not to bend the netting Wipe out cap screw or blow it out with compressed air Persons handling compressed air must...

Page 21: ...with gasket 2 Never re use this gasket Turn the engine over in the normal direction of rotation until compression is felt 25 Check valve clearances between rocker and valve stem using feeler gauge 1 see Chapter 3 1 If valve clearance is incorrect slacken off hex nut 2 Turn adjusting screw 3 with a screwdriver until feeler gauge 1 can just be pulled through between the rocker and the valve stem wit...

Page 22: ...pressure jet during engine cleaning Trace the cause of any contamination with oil and have the leak eliminated by a HATZ service station Install the air guide elements previously re moved The engine must never be run without the air guide elements in position Immediately after re assembly run the engine until warm to prevent residual moisture from causing rust 5 3 4 Checking threaded connections C...

Page 23: ...er Important Keep the entire area clean so that no dirt reaches the fuel Fuel particles may damage the injection system Always renew the fuel filter Note the arrows indicating the correct direction of fuel flow Open the fuel supply line or prime the pump until the fuel flows see Chapter 4 1 2 Run the engine briefly to check the fuel filter and lines for leaks 5 4 2 Dry type air cleaner maintenance...

Page 24: ...et 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 pape...

Page 25: ...r Injector not operating correctly Oil pressure lost Lower starting temperature limit exceeded Machinery not uncoupled Defective preheat system optional extra Set lever to START position Add fuel Check entire fuel supply system carefully If no fault is found supply line to engine fuel filter Function of delivery pump must be checked Check valve clearances adjust if necessary See workshop manual Se...

Page 26: ...p signal from monitoring el ement for automatic shutdown system optional extra oil pressure lost cylinder head temperature too high alternator has failed Check whether clear not turbid 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 adde...

Page 27: ...ator Battery and or other cable connections incorrectly con nected Cable connections loose Fuel supply is obstructed Tank run dry Fuel filter blocked Tank venting is inadequate Leaks at pipe unions Speed control lever does not remain in selected position Add fuel Renew fuel filter Check through entire fuel supply system Check engine oil level Activate mechanical oil pressure monitor Contact a HATZ...

Page 28: ...lve clearances Malfunction at injector Too much oil in engine Inadequate cooling Entire cooling air system contaminated Inadequate sealing at air guide plates Remove dirt from air cleaner Adjust valve clearances See workshop manual Drain off engine oil down to upper mark on dipstick Clean cooling air system Check that air guide plates and enclosure elements are all pres ent and make a tight seal 5...

Page 29: ...indicator light without delay 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 Do not splash electrical device with water jet or pressure jet during engine cleaning When carrying out welding work on the en gine or attached equipment attach the earth ground clip as near as po...

Page 30: ...29 ...

Page 31: ......

Page 32: ...TAL INFORMATION TO THE OWNER S MANUAL FOR MODEL YEAR 2015 EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION RELATED INSTALLATION INSTRUCTIONS 31 ...

Page 33: ... parts and engine operating conditions Maintenance instructions for EPA related engine parts Emission control system and adjustments Warranty statement Emission related installation instructions ENGINE PARTS AND OR EQUIPMENT RELATED TO EPA EXHAUST EMISSION REGULATIONS Parts which are mandatory for engine operation The following parts as manufactured according to HATZ specifications are mandatory f...

Page 34: ...ntact the nearest HATZ authorized Service Center for necessary repairs The engine is designed and adjusted to operate most efficiently at the following conditions Air temperature of 25 C 77 F Atmospheric pressure of 100 kPa 14 5 psi Relative humidity of 30 Operation of the engine at conditions other than above will affect performance and exhaust emissions Normally the equipment manufacturer takes ...

Page 35: ...he exhaust quality of the engines can be influenced by the execution the quality of execution of above described maintenance work Therefore the maintenance work has to be carried out by a qualified workshop Hatz authorised workshops for example are qualified workshops Hatz Diesel of America will give you respective addresses if required EMISSION CONTROL SYSTEM AND ADJUSTMENTS The emission control ...

Page 36: ...oper maintenance of your engine Your emission control system includes Fuel injection pump Injection nozzle Extra fuel device Crankcase breather valve assembly Air cleaner housing Intake manifold Exhaust manifold Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Information Labels Where a warrantable condition exists Motorenfabrik Hatz will repair your engine at no cost ...

Page 37: ... cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should be aware however that Motorenfabrik Hatz may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a Motorenfab...

Page 38: ...ers Model Year 2015 EPA certified engines and applies to the following exhaust emission related components Fuel injection pump Injection nozzle Extra fuel device Crankcase breather valve assembly Air cleaner housing Intake manifold Exhaust manifold Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Information Labels 37 ...

Page 39: ...rts This warranty is transferrable to subsequent owners only under the named warranty coverage conditions In order to obtain service under this warranty the retail purchaser should contact Hatz Diesel of America Inc at 262 544 0254 for information and the nearest service center The retail purchaser will not be charged for diagnostic labor which leads to the determination that a warranted part is d...

Page 40: ...enance you must place duplicate labels on the equipment EQUIPMENT LABELLING REQUIREMENTS FUEL LABEL Chapter 3 5 The fuel label has to be permanently attached to the equipment In case of an engine mounted fuel tank every engine is equipped with an additional fuel label nearby the fuel inlet Otherwise there are two loose fuel labels available with the engine If the original fuel label is not readily...

Page 41: ... exhaust system and related components consistent with the EPA emission regulation requirements Exhaust silencers and protection guard The exhaust silencer is fitted in connection with studs flat washers and hex nuts Fixation is done by Allen screws 1 2 4 4 1 2 4 4 3 2 3 3 1 23 Nm 17 lb ft A B C 3 40 1D90 V W ...

Page 42: ...equired HATZ Ident Nr 630 815 00 Assembly Assemble in reverse sequence Apply lubricant as specified by HATZ Torque to specification Ensure gasket kit is fitted in correct sequence i e the creased gaskets 3 face towards exhaust silencer A Assemble protection guard if so fitted in reverse sequence 4 1 B Use anti seize compound J as specified by HATZ Ensure the concave side of the curved washers 4 fa...

Page 43: ...e sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample with ambient air as follows Adding a 20 centimeter bended extension to the exhaust pipe 42 Engine type Ø d mm HATZ Ident Nr Clamp HATZ Ident Nr 1D90 V W 32 038 775 00 504 103 01 48 038 775 00 504 103 01 ...

Page 44: ...SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR THE USE OF EPA CERTIFIED ENGINES WITHIN CALIFORNIA 43 ...

Page 45: ...el ordiesel htm requirements Below is a description of applications for determining preempted equipment Please also see information regarding the federal non road engine emissions control program http www epa gov nonroad The following preemption list has been modified At the request of industry staff has removed the term Cleaners high pressure from the preemption list to avoid confusion with press...

Page 46: ... gutter Pipe layer Plows vibratory Post hole diggers Power pack hydraulic Pruner orchard Pumps 40 cc and above Rollers trench Sawmill portable Saws concrete masonry cutoff Screeners Shredder grinder Signal boards highway Silo unloaders Skidders Skid steer loaders Specialized fruit nut harvester Sprayers bituminous concrete curing crop field Stump cutters grinders Stumpbeater Surfacing equipment Sw...

Page 47: ...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 ...

Page 48: ... 0 2 20 01 14 4 0 0 1 1 Printed in Germany USA EPA IV Motorenfabrik Hatz GmbH Co KG Ernst Hatz Str 16 94099 Ruhstorf a d Rott Deutschland Tel 49 8531 319 0 Fax 49 8531 319 418 marketing hatz diesel de www hatz diesel com CREATING POWER SOLUTIONS ...

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