Operator`s Manual - The Official Tsurumi Pump Store

Operator`s Manual - The Official Tsurumi Pump Store
CREATING POWER SOLUTIONS.
1B20 | 1B27 | 1B30 | 1B40 | 1B50
OPERATOR’S MANUAL
Diesel engine
0000 433 802 10 - 01.2013 - 3
Printed in Germany
ENG
Hatz Diesel
www.HATZ-DIESEL.com
1B20, 1B27, 1B30, 1B40, 1B50
Table of contents
Table of contents
1
Notices .............................................................................................................
5
2
General information ........................................................................................
6
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
Safety ...............................................................................................................
General information ..........................................................................................
Intended use and foreseeable misuse ..............................................................
Machine user or machine manufacturer obligations .........................................
Representation of safety notes .........................................................................
Meaning of safety symbols ...............................................................................
Safety notes ......................................................................................................
Operational safety .............................................................................................
Machine-specific safety instructions for operation ............................................
Machine-specific safety instructions for maintenance work ..............................
Electrical equipment ..........................................................................................
Labels ...............................................................................................................
7
7
7
8
9
10
11
11
14
16
18
19
4
4.1
4.2
4.3
Technical data .................................................................................................
Engine ...............................................................................................................
Fuel ...................................................................................................................
Engine oil ..........................................................................................................
23
23
24
24
5
Engine design ................................................................................................. 26
6
6.1
6.2
6.3
Transport, assembly and commissioning ....................................................
Transport ...........................................................................................................
Assembly instructions .......................................................................................
Preparations for commissioning ........................................................................
28
28
28
29
7
7.1
7.2
7.3
7.4
7.4.1
7.4.2
7.5
7.5.1
7.5.2
7.6
7.7
7.8
7.8.1
7.8.2
Operation and use ..........................................................................................
Safety notes ......................................................................................................
Performing tests ................................................................................................
Setting the speed control ..................................................................................
Starting the engine ............................................................................................
Starting the engine with recoil start (up to -6 °C) ..............................................
Starting the engine with an electric starter ........................................................
Switching off the engine ....................................................................................
Switching off the engine (mechanical) ..............................................................
Switching off the engine (electrical) ..................................................................
Refueling ...........................................................................................................
Checking the water separator ...........................................................................
Checking the oil level and adding oil if necessary ............................................
Engine oil level ..................................................................................................
Oil level in the oil bath filter (option) ..................................................................
30
30
31
32
32
33
35
37
37
39
40
43
44
45
46
HATZ
Operator's Manual 1B20-1B50
3
Table of contents
1B20, 1B27, 1B30, 1B40, 1B50
8
8.1
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8
8.2.9
8.2.10
8.2.11
8.2.12
8.2.13
Maintenance ....................................................................................................
General maintenance instructions ....................................................................
Maintenance work .............................................................................................
Maintenance notice label ..................................................................................
Maintenance plan ..............................................................................................
Checking the intake area ..................................................................................
Change the engine oil .......................................................................................
Clean the oil filter ..............................................................................................
Check and set the tappet clearance .................................................................
Maintaining the oil bath filter .............................................................................
Clean the cooling air area .................................................................................
Check the screw connections ...........................................................................
Clean the exhaust screen .................................................................................
Changing the fuel filter ......................................................................................
Maintaining the dry air filter ...............................................................................
Checking and cleaning the air filter cartridge ....................................................
9
9.1
9.2
Faults ............................................................................................................... 77
Troubleshooting ................................................................................................ 77
Emergency start ................................................................................................ 83
10
10.1
10.2
Storage and disposal ...................................................................................... 86
Storing the machine .......................................................................................... 86
Disposing of the machine .................................................................................. 86
11
Installation declaration ................................................................................... 87
4
Operator's Manual 1B20-1B50
47
47
48
48
49
51
53
54
56
60
61
64
64
68
73
75
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
1
Notices
Notices
Contact data
© 2012
Motorenfabrik HATZ
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. +49 (0)8531 319-0
Fax +49 (0)8531 319-418
marketing@hatz-diesel.de
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 excerpts 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.
HATZ
Operator's Manual 1B20-1B50
5
General information
2
1B20, 1B27, 1B30, 1B40, 1B50
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 inhouse regulations apply.
Before commissioning, during operation and before maintenance work is begun 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
1B20, 1B27, 1B30, 1B40, 1B50
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 specialists there will repair your machine with Hatz original spare parts and
with HATZ tools. The global HATZ service network is at your disposal to advise you and supply you with spare parts. For the address of the Hatz service station nearest you, please see the directory included or visit the Internet at: www.hatz-diesel.com
Problems may occur if unsuitable spare parts are installed. We cannot accept responsibility for damage and secondary damage that result from this.
We therefore recommend the use of Hatz original spare parts. These parts
are manufactured according to strict Hatz specifications and achieve maximum operational reliability through their perfect fit and functionality. The order number can be found in the included 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, foreseeable misuse or failure to follow or adequately follow the safety measures and
procedures described in this Operator's Manual. This also applies to
changes made to the machine and use of unsuitable spare parts.
We reserve the right to make modifications in the interest of technical improvement.
6
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
3
Safety
3.1
General information
Safety
Introduction
This chapter contains the information you need to work safely with this machine.
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 functions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See the chapter 11 Installation declaration, page 87.
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 compromise the safety of the personnel working with the machine. Responsibility
is not accepted by Motorenfabrik HATZ for damage resulting from this situation.
The operational safety of the machine is only guaranteed if it is used as intended.
Use according to the intended purpose also includes observance of the instructions in this Operator's Manual.
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.
▪ Operation in flammable or hazardous environments.
▪ Operation in closed-off or poorly ventilated rooms.
HATZ
Operator's Manual 1B20-1B50
7
Safety
1B20, 1B27, 1B30, 1B40, 1B50
▪ 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.
▪ 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 are described in the chapter 3.2.2 Machine-specific
safety instructions for operation, page 14 and in the chapter 3.2.3 Machine-specific safety instructions for maintenance work, page 16, and in
other parts of the manual directly preceding the affected descriptions and instructions.
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 before installing the engine. These assembly instructions contain important information on how to safely install the engine and are available at your nearest 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 fulfills all safety-related requirements and legal regulations.
User obligations
The user is obligated to only operate the machine while it is in perfect condition. The user must check the condition of the machine before using it and
ensure that any defects are eliminated before it is taken into service. Operation of the machine while identified defects exist is not permitted. The user
must also ensure that the information contained in the Operator's Manual
has been read and understood.
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 be able to demonstrate
the necessary qualifications for working with this equipment, acquired in
training/instructional courses. No one may work with the machine without the
necessary qualifications, even if for just a brief period.
All work performed on the machine must be in compliance with the information provided in the Operator's Manual.
8
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
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 accessible 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 technology 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:
▪ Warning 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.
Signal words
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
Warning symbol/
Signal word
HATZ
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.
Operator's Manual 1B20-1B50
9
Safety
1B20, 1B27, 1B30, 1B40, 1B50
Warning symbol/
Signal word
Meaning
CAUTION
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
NOTICE
This signal word indicates additional useful information, such as operating tips and cross references.
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!
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
10
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Symbol
Safety
Meaning
Warning of heavy loads!
Warning of environmental damage!
Comply with the Operator's Manual or additional documentation from other manufacturers or the user.
Additional information that is useful to the reader.
i
3.2
Safety notes
3.2.1 Operational safety
Introduction
This chapter contains all of the important safety instructions for personal protection and for safe and reliable operation. Additional, task-related safety instructions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury or danger of property damage due to failure to comply with the Operator's Manual and
the safety instructions contained therein.
HATZ
▪
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.
Operator's Manual 1B20-1B50
11
Safety
1B20, 1B27, 1B30, 1B40, 1B50
Using the machine
▪ Only operate the machine for the purposes described in the chapter 3.1.1
Intended use and foreseeable misuse, page 7.
Compliance with other regulations
▪ Adhere to the applicable accident prevention regulations of the trade associations.
▪ Comply with the regulations concerning the minimum safety and health requirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regulations also apply when operating the machine.
Operating personnel
▪ The machine may only be operated by qualified personnel. The personnel
must have read and understood this Operator's Manual or must be able to
demonstrate the necessary qualifications for working with this equipment,
acquired in training/instructional courses.
▪ The operating personnel must not be under the influence of drugs, medication or alcohol.
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 operating steps.
Personal protective
equipment
Safety shoes
Pictogram
Function
Safety shoes offer protection
against:
▪ Slipping
▪ Falling objects
12
Hearing protection
Hearing protection offers protection against ear injuries due to
excessive and constant noise.
Safety gloves
Safety gloves protect the hands
against injury, for example from
battery acid.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
Personal protective
equipment
Pictogram
Function
Safety goggles
(with side shields)
Safety goggles protect the eyes
from flying objects (for example,
dust particles, spraying liquids,
spraying acid).
Working clothes
Wear close-fitting clothing. However, it must not restrict the
wearer's freedom of movement.
Warning and notice labels on the machine
The warning and notice labels on the machine must be followed (see the
chapter 3.3 Labels, page 19).
The warning and notice labels 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 the chapter 2 General
information, 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.
General safety notes
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in the Operator's Manual.
▪
HATZ
Heed the warnings on the machine and in the Operator's
Manual.
Operator's Manual 1B20-1B50
13
Safety
1B20, 1B27, 1B30, 1B40, 1B50
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪
The personnel must have read and understood this Operator's Manual or must be able to demonstrate the necessary
qualifications for working with this equipment, acquired in
training/instructional courses.
▪
Only qualified personnel is permitted to operate and maintain this machine.
▪
Failure to comply will cause the warranty to be void.
WARNING
Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the
machine.
▪
Follow all instructions.
▪
Do not perform activities that are not authorized. 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 location can lead to injuries (of the back, for example).
▪
Only lift the machine with a hoist (see the chapter 6.1 Transport, page 28).
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 machine-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 before installing the engine.
These assembly instructions contain important information on safe installation.
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 determined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations .
14
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
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.
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪
Only refuel while 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.
CAUTION
Danger of injury from faulty starter rope.
A chafed starter rope can rip and cause injuries.
▪
HATZ
Before using the starter rope, check for abrasion; replace
the rope if necessary.
Operator's Manual 1B20-1B50
15
Safety
1B20, 1B27, 1B30, 1B40, 1B50
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.
▪ 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 parts, we recommend the use of HATZ original spare
parts (see the 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.
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 generate
an explosive gas-air mixture.
▪
16
Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
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 the maintenance instructions are not followed.
▪
Only perform maintenance while the engine is switched off.
▪
In engines with a starter:
Disconnect the negative terminal of the battery.
Protect the starting key against unauthorized access.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
HATZ
Let the engine cool before maintenance.
Operator's Manual 1B20-1B50
17
Safety
1B20, 1B27, 1B30, 1B40, 1B50
3.2.4 Electrical equipment
Safety notes
DANGER
Danger to life, danger of injury or danger of property damage due to incorrect use of batteries.
▪
Do not place tools on the battery.
▪
Before performing work on the electrical equipment, always
disconnect the negative terminal of the battery.
▪
Never swap the positive (+) and negative (–) battery terminals.
▪
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 contact of current-carrying cables.
▪
If faults occur, check the cable connections for good contact.
DANGER
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪
Keep batteries away from open flames and incendive
sparks.
▪
Do not smoke when working with batteries.
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
18
▪
Protect your eyes, skin and clothing from the corrosive battery acid.
▪
Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
NOTICE
▪
The necessary wiring diagrams are included with the machine 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 voltage peaks could destroy the electronic components.
▪ When performing a manual emergency start, leave the (possibly depleted)
battery connected.
▪ 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 connection to the voltage regulator.
▪ The following additionally applies before starting emergency operation
without the battery:
– In models with an instrument box on the engine, disconnect the plugin connection to the voltage regulator. Turn the starting key to pos. "0"
and remove.
– In models with an external instrument box, disconnect the plug-in connection to the instrument box.
3.3
Labels
Overview
The following labels are found on the machine:
▪ Engine type plate
▪ Warning labels and information signs on the engine
HATZ
Operator's Manual 1B20-1B50
19
Safety
1B20, 1B27, 1B30, 1B40, 1B50
Engine type plate
➁
➀
➂
➃
The engine type plate is located on the sound protection hood and contains
the following engine information:
1
Engine type
2
Code (special models only)
3
Engine serial number (engraved on the crankcase)
4
Max. engine speed (rpm)
These data must always be specified for requests and spare part orders.
Warning labels and information signs
Label
Meaning
EX
IN
Maintenance instructions (see the
chapter 8.1 General maintenance instructions, page 47)
1B20: 0,20mm 1B27: 0,10mm
1B30: 0,10mm 1B40: 0,10mm
1B50: 0,10mm
0000 051 104 06
250h
max
OIL
= 1h
500h
max
20
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Safety
Label
Meaning
1
2
3
Starting the engine with recoil start
(see the chapter 7.4.1 Starting the
engine with recoil start (up to -6 °C),
page 33)
0000 051 300 02
CAUTION
Danger of injury from faulty starter
rope.
0000 053 338 01
A chafed starter rope can rip and
cause injuries.
▪ Before using the starter rope,
check for abrasion; replace the
rope if necessary.
Speed adjustment with connecting
rod (additional equipment)
BIO
DIESEL
052 356 02
Refuel with diesel fuel only. For the
specification, see the chapter 4.2
Fuel, page 24
Do not use bio diesel.
HATZ
Operator's Manual 1B20-1B50
21
Safety
1B20, 1B27, 1B30, 1B40, 1B50
Label
Meaning
Changing the fuel filter
S
E
356
052
D
I
01
E
LB
I
O
(see the chapter 8.2.11 Changing
the fuel filter, page 68)
22
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
4
Technical data
4.1
Engine
Type
Technical data
1B20
Type
1B27
1B30
1B40
1B50
Air-cooled four stroke diesel engine
Combustion system
Direct injection
Number of cylinders
1
1
1
1
1
Bore/stroke
mm
69 / 65
74 / 65
80 / 69
88 / 76
93 / 76
Displacement
cm3
243
280
347
462
517
Tank capacity
Ltr.
3
3
5
5
5
Engine oil capacity
Without oil sump
Approx. ltr.
0,9 1)
0,9 1)
1,1 1)
1,5 1)
1,5 1)
With oil sump
Approx. ltr.
2,6 1)
-
2,8 1)
3,2 1)
-
Without oil sump
Approx. ltr.
0,5 1)
0,5 1)
0,5 1)
0,8 1)
0,8 1)
With oil sump
Approx. ltr.
1,6
1,8
2,2
Engine oil consumption
(after running-in period)
Max.
1% of fuel consumption, pertaining to full load
Engine oil pressure at oil
temperature of 100 °C
Approx.
Difference between the
"max." and "min." mark
1)
-
1)
-
2.5 bar at 3000 rpm
Sense of rotation on power
take-off side
Tappet clearance
at 10 - 30 °C
Inlet/Outlet
1)
Left
mm
0,20 2)
Max. perm. inclination during continuous operation in
direction
0,10 2)
0,10 2)
0,10 2)
0.10 2)
Flywheel low 25° 3)
Other directions 35° 3)
Weight (incl. fuel tank, air
filter, silencer, recoil start
and electric start)
Approx. kg
Battery capacity
Min / max
33
34
40
55
56
12 V – 36/60 Ah/24 V – 24/44 Ah
These values are approximations only. The correct level is indicated by the
max. mark on the dipstick (see the chapter 7.8 Checking the oil level and
adding oil if necessary, page 44).
1)
HATZ
Operator's Manual 1B20-1B50
23
Technical data
1B20, 1B27, 1B30, 1B40, 1B50
If equipped with an automatic valve lash adjustment, the tappet clearance does not need to be checked (see the chapter 8.2.2 Maintenance plan,
page 49).
2)
3)
Exceeding these limit values causes engine damage.
Screw tightening torque
4.2
Designation
Nm
Oil drain screw
50
Fuel
Fuel type
All types of diesel fuel that meet the minimum requirements of the following
specifications are suitable:
▪ EN 590 or
▪ BS 2869 A1 / A2 or
▪ ASTM D 975- 1D / 2D
CAUTION
Danger of engine damage from low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪
The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
Winter fuel
When outside temperatures drop below 0 °C, use winter fuel or mix in petroleum in advance:
Lowest ambient temperature at start [°C]
4.3
Percentage of petroleum [%] for
Summer fuel
Winter fuel
0 to -10
20
‑
-10 to -15
30
‑
-15 to -20
50
20
-20 to -30
‑
50
Engine oil
Engine oil
All oil brands that meet at least one of the following specifications are suitable:
▪ ACEA – B2 / E2 or better
▪ API – CD / CE / CF / CF-4 / CG-4 or better
24
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Technical data
If engine oils of a low quality standard are used, the oil change interval must
be reduced to 150 operating hours.
Oil viscosity
0
14
-10
-4
-20
-22
-30
-40
-40
40
10
32
30
20
50
15W/40
30
68
10W/40
40
86
10W/30
50
104
5W/40
122
OIL: SAE...
10W
°C
5W/30
°F
Choose the recommended viscosity based on the type of start (recoil, crankhandle or electric) and on the engine temperature at which the engine will be
operated.
CAUTION
Engine damage from unsuitable engine oil.
Using engine oil that does not meet the above specifications
considerably shortens the engine service life.
HATZ
Operator's Manual 1B20-1B50
25
Engine design
5
1B20, 1B27, 1B30, 1B40, 1B50
Engine design
Overview
2
22
21
20
19
3
18
4
17
5
16
6
15
7
26
1
8
9
10
9
11
Pos.
Designation
1
Type plate
2
Cylinder head cover
3
Silencer with contact protection
4
Exhaust manifold with exhaust screen
5
Oil pressure switch 1)
6
Starter 1)
7
Voltage regulator 1)
8
Crankshaft – power take-off (pto)
9
Oil drain screw
10
Speed control lever
11
Screw cap for oil filter
12
Engine fixation
13
Starting key 1)
14
Indicators 1)
Operator's Manual 1B20-1B50
12
13
14
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Pos.
Designation
15
Intake opening for cooling and combustion air
16
Oil filling opening and dipstick
17
Recoil start
18
Stop pin (option)
19
Dry air filter
20
Lifting eye
21
Fuel cap
22
Sound protection hood
1)
Engine design
Only in model with electrical equipment.
The engine can optionally be supplied with an external instrument box.
HATZ
Operator's Manual 1B20-1B50
27
Transport, assembly and commissioning
1B20, 1B27, 1B30, 1B40, 1B50
6
Transport, assembly and commissioning
6.1
Transport
Safety notes
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪
Only lift the machine with a hoist.
CAUTION
Only use lifting lugs for transporting the engine.
Do not use for lifting the entire equipment.
NOTICE
Danger of environmental damage from leaking fluid.
If the machine is tilted, engine oil and diesel fuel can run out.
▪
Only transport the machine in an upright position.
Transport conditions
▪ Only lift the engine by the standard fitted lifting lugs.
▪ When transporting the machine, follow the safety instructions.
▪ When transporting, follow the applicable safety and accident prevention
regulations of the trade associations.
▪ After delivery, check the machine for completeness and transport damage.
▪ Only transport the machine when it is switched off and has cooled down.
▪ If you have questions on transporting the machine, please contact your
nearest HATZ service station. For contact data, see the chapter 1 "Notices", page 5 or www.hatz-diesel.com.
6.2
Assembly instructions
Assembly notes
HATZ diesel engines are efficient, robust and long-lived. Therefore, they are
usually installed in machines that are used for commercial purposes.
The machine manufacturer must follow the applicable regulations regarding
machine safety – the engine is a part of a machine.
28
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Transport, assembly and commissioning
Depending on the use and installation of the engine, it may be necessary for
the machine manufacturer and machine user to install safety equipment to
prevent inappropriate use. Note the following:
▪ Parts of the exhaust gas system and the engine surface become hot during operation and may not be touched until they cool down after the engine is switched off.
▪ Incorrect cable connections and incorrect operation of the electrical equipment can lead to sparking and must be avoided.
▪ After the engine is installed in the machine, rotating parts must be protected against contact.
HATZ safety equipment is available for the belt drive of the cooling fan and
alternator.
▪ Comply with all notice and warning labels on the engine and keep them in
a legible condition. If a label should become detached or be difficult to
read, it must be replaced promptly. For this purpose, contact your nearest
HATZ service station.
▪ Any improper modification of the engine results in a loss of liability coverage for resulting damage.
Only regular maintenance, as specified in this Operator's Manual, will maintain the operating readiness of the engine.
The assembly instructions contain important information on how to safely assemble the engine. They are available from any Hatz service station.
If you have any questions, please contact your nearest HATZ service station before commissioning the engine.
6.3
Preparations for commissioning
▪ Check the delivered parts for completeness, damage and other noticeable
issues.
▪ Ensure that the setup location is adequately ventilated.
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.
HATZ
▪
Never operate the machine in closed-off or poorly ventilated
rooms.
▪
Do not breathe in the exhaust gases.
Operator's Manual 1B20-1B50
29
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
7
Operation and use
7.1
Safety notes
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in the chapter 3 Safety,
page 7.
DANGER
Danger to life due to damage and defects on the machine.
▪
Do not take the machine into service if damage has been localized and identified.
▪
Replace faulty components.
WARNING
Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the
machine.
▪
Define the responsibilities of the personnel taking the machine into service.
▪
Replace faulty machine parts immediately.
▪
Check the installation conditions when the machine is first
taken into service and after the machine has been inactive
for a lengthy period.
CAUTION
Danger of engine damage from low load operation.
Operating the engine at no load or at very low load for an extended period can impair the running characteristics of the engine.
30
▪
Ensure that the engine load is at least 15 %.
▪
Before switching off the engine following low load operation,
briefly operate it at a considerably higher load.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
CAUTION
Exceeding of the permissible forces at the speed control
lever and stop pin can cause damage to the stops and inside regulator parts.
Please note the following figure.
Max. permissible forces on the speed control lever
F < 15 N STOP
F < 30 N
M < 2.3 Nm
76.5°
STOP
7.2
START
Performing tests
Before starting
Before starting the engine, several tests need to be performed to ensure the
machine is working properly.
Procedure
HATZ
Step
Test
1
The machine is standing securely and on a level surface.
2
The installation location is adequately ventilated.
3
There is a sufficient amount of fuel in the fuel tank (see the chapter 4.2 Fuel, page 24).
4
There is a sufficient amount of engine oil in the engine housing
(see the chapter 4.3 Engine oil, page 24).
5
The starter rope of the recoil start does not exhibit abrasion
(hand start).
6
The oil bath filter (option) is filled with engine oil (see the chapter
7.8.2 Oil level in the oil bath filter (option), page 46).
Operator's Manual 1B20-1B50
31
Operation and use
7.3
1B20, 1B27, 1B30, 1B40, 1B50
Setting the speed control
Safety note
CAUTION
Damage to the diesel engine due to inadequate lubrication.
▪
After the engine has been out of use for an extended period
(approx. 6 months or longer) or when the engine is first taken into service, operate the engine at a low set speed and
without a load for approx. 20 seconds after starting. This ensures good lubrication of all bearing points before the speed
and load are increased.
Overview
Procedure
Step
Activity
1
First move the speed control lever (1) to the "Stop" position.
2
Depending on the possibility or requirement, place the speed
control lever in either the "1/2" or "Start" position.
Note:
A lower speed setting will cause less exhaust smoke when starting.
7.4
Starting the engine
Starting options
The standard equipment of the engine is a hand start mechanism. A starter
can be installed as an option.
If possible, separate the engine from the machine being driven by uncoupling it. Always switch the machine into idle mode.
32
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
Safety notes
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.
WARNING
Danger of injury from faulty starter rope.
A chafed starter rope can rip and cause injuries.
▪
Before using the starter rope, check for abrasion; replace
the rope if necessary.
CAUTION
Danger of injury and danger of engine damage from the use
of starting fluid.
▪
Danger of injury during hand starting because the use of
starting fluid can result in uncontrolled ignitions.
▪
Engine damage from uncontrolled ignitions.
▪
Never use starting fluid.
7.4.1 Starting the engine with recoil start (up to -6 °C)
Overview
HATZ
Operator's Manual 1B20-1B50
33
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Pos.
Designation
1
Grip
2
Recoil start cover
3
Diagram of starting procedure
Procedure
Step
Activity
1
Check the speed control (see the chapter 7.3 Setting the speed
control, page 32).
2
Slowly pull out the grip with the rope until you encounter a slight
resistance.
3
Let the rope run back in to be able to use the entire rope length
for the starting procedure.
4
Hold the grip with both hands.
5
Pull the starting rope evenly and with increasing speed (do not
tear at it jerkily) until the engine starts.
NOTICE
When the exhaust emits white smoke after several failed
start procedures:
i
34
▪
Move the speed controller lever to the "Stop" position.
▪
Pull the starting rope all the way out five times.
▪
Readjust the speed control (see the chapter 7.3 Setting the
speed control, page 32).
▪
Repeat the start procedure.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
7.4.2 Starting the engine with an electric starter
Overview
Standard
Option
Pos.
Designation
A
Indicators
1 – Operating display
2 – Charge control
3 – Oil pressure display
4 – Engine temperature display (option)
5 – Pre glow display (option)
B
Ignition lock
0 – Off
I – Operation
II – Starting
Procedure
NOTICE
i
HATZ
▪
Start for max. 30 seconds. If the engine still is not running
after that, turn the starting key back to position "0" and eliminate the cause (see the chapter 9 Faults, page 77).
▪
Turn the starting key to position "0" every time you want to
start the engine.
▪
The anti-repeat device in the ignition lock makes it impossible for the starter to engage while the engine is running and
become damaged.
Operator's Manual 1B20-1B50
35
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
1
Check the speed control (see the chapter ).
2
Insert the starting key all the way and turn to position "I".
Depending on the model, the following indicators light up:
▪ Charge control (2)
▪ Oil pressure display (3)
▪ Pre glow display (5)
NOTES:
▪ If the engine temperature display (4) lights up, the cylinder
head temperature is impermissibly high. Do not start the engine; eliminate the cause.
▪ When the optional pre glow display (5) goes out, continue with
step 3.
3
Turn the starting key to position "II".
4
As soon as the engine is running, release the starting key.
▪ The starting key springs back to position "I" and remains in
this position during operation.
▪ The charge control (2) and oil pressure display (3) go out.
▪ The operating display (1) lights up.
NOTICE
i
▪
In case of irregularities, switch off the engine immediately.
▪
Identify the fault and eliminate it.
▪
For details of troubleshooting, see the chapter 9 Faults,
page 77.
Electrical automatic shutoff (additional equipment)
The distinguishing feature of the electrical automatic shutoff is brief flashing
of all indicators after turning the starting key to position "I".
36
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
NOTICE
i
7.5
▪
If the engine stops again immediately after starting, or stops
independently during operation, this is an indication that a
monitoring element of the automatic shutoff has been activated.
▪
Remedy the malfunction before further starting attempts
(see the chapter 9.1 Troubleshooting, page 77).
▪
Despite the automatic shutoff, check the oil level every 8-15
operating hours (see the chapter 7.8 Checking the oil level
and adding oil if necessary, page 44).
▪
If the fuel shutoff valve (additional equipment) is blocked
due to an electrical fault of the fuel supply and the engine
therefore does not start, an emergency start can be carried
out (see the chapter 9.2 Emergency start, page 83).
Switching off the engine
Procedures
The engine can be switched off in different ways depending on how it is
equipped:
▪ Speed control lever (mechanical)
▪ Stop pin (mechanical)
▪ Starting key (electrical)
7.5.1 Switching off the engine (mechanical)
NOTICE
i
HATZ
Engines with a blocked lower idle speed cannot be switched off
with the speed control lever. In this case, the engine is switched
off with the stop pin or starting key, depending on how the engine is equipped.
Operator's Manual 1B20-1B50
37
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Overview
Pos.
Designation
1
Speed control lever
2
Stop pin (additional equipment)
3
Connecting rod (additional equipment)
Procedure
Step
Activity
Speed control lever
1
Push the speed control lever (1) all the way to the "STOP" position. The engine switches off.
Stop pin
1
Press and hold the stop pin (2) until the engine switches off.
2
Release the stop pin and ensure that it returns to its original
position.
Speed adjustment with connecting rod (additional equipment)
1
38
Move the speed adjustment with the connecting rod (3) to the
"STOP" position and press it until the engine switches off.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
7.5.2 Switching off the engine (electrical)
Safety notes
CAUTION
Danger of injury due to operation by unauthorized persons.
There is a danger of injury if unauthorized persons handle the
machine.
▪
Remove the starting key and protect it against unauthorized
access during breaks in operation or after finishing work for
the day.
Overview
Standard
Option
Procedure
NOTICE
i
Danger of full battery discharge.
▪
When the machine is switched off, always turn the starting
key to position "0" or else the battery may become fully discharged.
Step
Activity
1
Turn the starting key to position "0".
▪ The engine switches off.
▪ All indicator lamps go out.
2
HATZ
Remove the starting key.
Operator's Manual 1B20-1B50
39
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Automatic electrical switch-off with fault storage
This is identified by brief flashing of all indicators after the starting key is
turned to position "I".
NOTICE
i
If the engine stops again immediately after starting, or stops independently during operation, this is an indication that a monitoring element of the automatic shutoff has been activated.
Procedure
Step
Activity
1
Check the indicators (2-4).
After the engine comes to a standstill, the fault will continue to
be displayed by the indicator for approx. another 2 minutes.
2
Then the electrical equipment switches off automatically.
3
Set the starting key to position "0".
4
Turn the starting key back to position "I".
The fault display lights up again.
Remedy the fault before further starting attempts (see the
chapter 9 Faults, page 77).
The indicator goes out at the next start.
7.6
Refueling
Safety notes
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
40
▪
Only refuel while 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.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
CAUTION
Danger of environmental damage from spilled fuel.
Do not overfill the fuel tank and do not spill fuel.
▪
Collect emerging fuel and dispose of it in an environmentally
compatible manner.
CAUTION
Engine damage from using low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪
Only use the fuel specified in the chapter 4.2 Fuel, page 24.
▪
The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
Overview
HATZ
Pos.
Designation
1
Fuel cap
2
Fuel tank
Operator's Manual 1B20-1B50
41
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Procedure
Step
Activity
1
Open the fuel cap.
2
Fill the fuel tank with diesel
fuel.
3
Close the fuel cap.
Figure
NOTICE
i
42
▪
Before starting for the first time or if the fuel system is empty, fill the fuel tank fully with diesel fuel. This causes the fuel
system to be bled automatically.
▪
Automatic bleeding is completed after a waiting period of
1-2 minutes. The engine is ready to start.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
7.7
Operation and use
Checking the water separator
Safety notes
CAUTION
Danger of environmental damage from spilled fuel.
When water is drained from the water separator, a small amount
of fuel is drained as well.
▪
Catch the emerging water-fuel mixture and dispose of it in
an environmentally compatible manner.
NOTICE
i
The interval for checking the water separator depends entirely
on the proportion of water in the fuel and on the care exercised
during refueling; the water separator should be checked at least
once a week.
Overview
Water in the fuel tank collects at the lowest point of the fuel tank in the water
separator.
Standard
HATZ
Model with window
Pos.
Designation
1
Drain screw, hex (standard)
2
Window (additional machine)
3
Drain screw (manually operated)
Operator's Manual 1B20-1B50
43
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
Procedure
Step
Activity
1
Model with window:
Check the window (2) for water content.
Collected water can be clearly identified by the noticeable separating line between the water and the diesel fuel above it.
2
Place a suitable container under the drain screw (1) or (3).
NOTE: In inaccessible locations, an extension hose can be
mounted on the drain screw (3).
7.8
3
Open the drain screw (1) or (3) and drain the water into the container.
4
When fuel emerges, close the drain screw.
5
Dispose of the water-fuel mixture in an environmentally compatible manner.
Checking the oil level and adding oil if necessary
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Wear safety gloves.
CAUTION
Danger of later engine damage.
44
▪
Operating the engine with an oil level below the min. mark
or above the max. mark can lead to engine damage.
▪
When checking the oil level, the machine must be horizontal
and the engine must be switched off.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Operation and use
7.8.1 Engine oil level
Overview
Pos.
Designation
1
Dipstick
2
Oil refilling container
Procedure
HATZ
Step
Activity
1
Switch off the engine and wait several minutes for the engine oil
to collect in the crank housing. The machine must be horizontal.
2
Remove contamination on the engine in the area of the dipstick.
3
Unscrew the dipstick and clean it.
4
Reinsert the dipstick and screw it tight.
5
Unscrew the dipstick and check the oil level.
6
If the oil level is close to the min. mark, add engine oil to the
max. mark.
7
Reinsert the dipstick and screw it tight.
Operator's Manual 1B20-1B50
45
Operation and use
1B20, 1B27, 1B30, 1B40, 1B50
7.8.2 Oil level in the oil bath filter (option)
Overview
Pos.
Designation
1
Oil container
2
Filter insert
3
Gasket
4
Lock
Procedure
46
Step
Activity
1
Remove the oil container (1) and fill it to the mark with engine
oil.
2
Insert the long end of the filter insert (2) into the oil container.
3
Mount the oil container, ensuring that the gasket (3) is properly
positioned and the locks (4) are correctly fastened.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
8
Maintenance
8.1
General maintenance instructions
Safety notes
WARNING
Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the
machine.
▪
Follow all instructions.
▪
Do not perform activities that are not authorized. Contact
properly trained personnel if necessary.
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in the chapter 3 Safety,
page 7.
▪ Maintenance tasks may only be performed by trained personnel.
▪ Accident prevention measures must be in accordance with the local accident prevention regulations.
▪ Perform setting and maintenance work at the specified intervals.
▪ Replace faulty machine parts as soon as possible.
▪ Always use personal protective equipment.
▪ Only use fully functional tools.
▪ Problems may occur if unsuitable spare parts are installed. We cannot accept responsibility for damage and secondary damage that result from
this. We therefore recommend the use of Hatz original spare parts.
▪ Closely adhere to the maintenance conditions prescribed in this Operator's
Manual.
▪ Only make changes on the machine in agreement with the manufacturer.
▪ Only perform maintenance while the engine is switched off.
▪ Adhere to legal regulations when handling and disposing of used oil, filters
and cleaning agents.
▪ Protect the starting key against unauthorized access.
▪ For engines with a electric starter: disconnect the negative battery terminal.
▪ After completing maintenance work, check that all tools, bolts, aids and
other objects are removed from the machine and that all safety equipment
has been replaced.
HATZ
Operator's Manual 1B20-1B50
47
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
▪ Before starting, ensure that no persons are located in the danger zone of
the engine or machine.
Performance of maintenance work
The entire machine is designed to be maintenance friendly. Parts that require maintenance are easily accessible.
▪ Perform maintenance work faithfully at the specified intervals to prevent
premature wear of the machine.
▪ Follow the notice and warning labels on the machine.
▪ Always retighten screw connections loosened during maintenance work.
▪ After the necessary maintenance and repair work is completed, perform a
function test (test run).
▪ For maintenance work that is not listed and described in the maintenance
documentation, please contact your nearest HATZ service station.
8.2
Maintenance work
Safety note
CAUTION
Danger of injury if the maintenance instructions are not followed.
▪
Only perform maintenance while the engine is switched off.
▪
Protect the starting key against unauthorized access.
▪
For engines with a starter: disconnect the negative battery
terminal.
▪
After the maintenance work is completed, ensure that all
tools have been removed from the machine.
8.2.1 Maintenance notice label
NOTICE
i
48
Depending on whether or not the engine is equipped with an automatic valve lash adjustment, the appropriate maintenance plan
shown here is supplied with the engine.
It should be mounted on the engine in a clearly visible location.
The maintenance intervals specified on the maintenance plan
must be adhered to (see the chapter 8.2.2 Maintenance plan,
page 49).
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
Model without automatic valve lash adjustment
EX
IN
1B20: 0,20mm 1B27: 0,10mm
1B30: 0,10mm 1B40: 0,10mm
1B50: 0,10mm
0000 051 104 06
250h
max
OIL
= 1h
500h
max
Model with automatic valve lash adjustment
AUTOM.
EX
IN
0000 052 502 02
250h
max
OIL
= 1h
500h
max
8.2.2 Maintenance plan
The interval at which maintenance work should be performed on the fuel filter depends on the cleanliness of the fuel in use and may need to be shortened to 250 operating hours.
HATZ
Operator's Manual 1B20-1B50
49
Maintenance
Symbol
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance interval
Maintenance activity/check
Every 8-15 oper- Check the oil level.
ating hours or every day before
starting
Check the engine oil level in
the bottom section of the oil
bath filter and examine the oil
for contamination. Change the
oil if it is sludgy.
Chapter
7.8 Checking the
oil level and adding oil if necessary, page 44
8.2.7 Maintaining
the oil bath filter,
page 60
In models with a cyclone precleaner: remove the dust trap.
250h
50
Check the intake area of the
combustion and cooling air.
8.2.3 Checking
the intake area,
page 51
Check the air filter maintenance indicator.
8.2.12 Maintaining the dry air filter, page 73
Check the water separator.
7.7 Checking the
water separator,
page 43
Every 250 operat- Maintain the oil bath filter.
ing hours
8.2.7 Maintaining
the oil bath filter,
page 60
Change the engine oil.
8.2.4 Change the
engine oil,
page 53
Check and adjust the tappet
clearance (not in models with
an automatic valve lash adjustment).
8.2.6 Check and
set the tappet
clearance,
page 56
Clean the cooling air area.
8.2.8 Clean the
cooling air area,
page 61
Check the screw connections.
8.2.9 Check the
screw connections, page 64
Clean the exhaust screen.
8.2.10 Clean the
exhaust screen,
page 64
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Symbol
500h
Maintenance
Maintenance interval
Maintenance activity/check
Every 500 operat- Change the fuel filter.
ing hours
Maintain the dry air filter.
Every 1000 oper- Clean the oil filter.
ating hours
Chapter
8.2.11 Changing
the fuel filter,
page 68
8.2.12 Maintaining the dry air filter, page 73
8.2.5 Clean the
oil filter,
page 54
In new and generally overhauled engines, after 25 operating hours:
▪ Change the engine oil
▪ Check the tappet clearance and adjust if necessary
▪ Check the screw connections (do not retighten the screws for attaching
the cylinder head)
In case of a low number of operating hours, change the engine oil no later
than every 12 months, regardless of the actual number of operating hours.
8.2.3 Checking the intake area
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Let the engine cool.
▪
Wear safety gloves.
NOTICE
i
HATZ
In case of heavy contamination, shorten the maintenance intervals accordingly (see the chapter 8.2.2 Maintenance plan,
page 49).
Operator's Manual 1B20-1B50
51
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Overview
Standard
Model with cyclone
precleaner
Pos.
Designation
1
Air intake opening
2
Intake area of cyclone precleaner
3
Dust outlet opening
4
Intake area of oil bath filter
Model with oil bath filter
Procedure
Step
Activity
1
Check the air intake opening (1) for coarse contamination such
as leaves, heavy dust deposits, etc., and clean if necessary.
2
In models with a cyclone precleaner, also check and if necessary clean the intake area (2) in addition to step 1.
Check that the dust outlet opening (3) is clear and clean it if
necessary.
3
52
In models with an oil bath filter, also check and if necessary
clean the intake area (4) in addition to step 1.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
8.2.4 Change the engine oil
Safety notes
CAUTION
Danger of burns.
When working on the engine there is a danger of burns from hot
oil.
▪
Wear personal protective equipment (gloves).
▪
Collect the used oil and dispose of it according to local environmental regulations.
NOTICE
i
▪
The engine must be level.
▪
The engine must be switched off.
▪
Only drain engine oil while it is warm.
▪
The engine oil should be changed when the oil filter is
cleaned (see the chapter 8.2.5 Clean the oil filter,
page 54), since oil will run out when the filter is pulled out.
Overview
Without oil sump
HATZ
Pos.
Designation
1
Oil drain screw
2
Gasket
With oil sump
Operator's Manual 1B20-1B50
53
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Procedure
Step
Activity
1
Unscrew the oil drain screw (1) and drain the oil entirely.
2
If necessary (every 1000 operating hours), clean the oil filter as
per chapter 8.2.5 Clean the oil filter, page 54.
3
Screw in the cleaned oil drain screw (1) with the new gasket
(2) and tighten.
Tightening torque: 50 Nm.
4
Add engine oil (see the chapter 4.3 Engine oil, page 24).
8.2.5 Clean the oil filter
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Let the engine cool before maintenance.
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
▪
Wear safety goggles.
▪
Never direct the compressed air jet toward people or toward
yourself.
NOTICE
i
54
▪
Capture emerging oil in a suitable container.
▪
Dispose of the oil according to legal regulations.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
NOTICE
i
▪
The oil filter should be cleaned when the engine oil is
changed (see the chapter 8.2.4 Change the engine oil,
page 53) since oil will run out when the filter is pulled out.
▪
The machine must be level when cleaning the oil filter.
Procedure
HATZ
Step
Activity
1
Loosen the screw (1) by approx. five turns.
2
Pull the oil filter (2) out of the
housing.
3
Blow out the oil filter with compressed air from the inside to
the outside.
Figure
Operator's Manual 1B20-1B50
55
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
4
Check the gasket (3) for damage and renew if necessary.
5
Lightly oil the gaskets (3+4)
before mounting.
6
Insert the oil filter and press it
all the way in.
7
Before tightening the screw,
ensure that the tension springs
(5) rest against the oil filter at
both ends.
Figure
Tighten the screw.
8
Check the oil level and add oil
to the max. mark if necessary
(see the chapter 4.3 Engine
oil, page 24).
8.2.6 Check and set the tappet clearance
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine. Only
perform the settings while the engine is cold (10-30 °C).
▪
Let the engine cool.
NOTICE
i
56
This chapter only applies to engines without an automatic valve
lash adjustment.
This can be identified on the supplied maintenance plan (see the
chapter 8.2.2 Maintenance plan, page 49).
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
Preparations
The preparations are performed in different ways depending on how the engine is equipped:
▪ Preparations on engine model with dry air filter
▪ Preparations on engine model with oil bath filter
▪ Preparations on engine model with rammer operation (1B20 R)
Preparation - Engine model with dry air filter
Step
Activity
1
Unscrew the air filter cap (1).
2
Remove the sound protection
hood (2).
Figure
Preparation - Engine model with oil bath filter
HATZ
Step
Activity
1
Release the screw (1).
2
Take off the cover plate (2)
with the sound protection hood
(3).
Figure
Operator's Manual 1B20-1B50
57
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Preparations - Engine model with rammer operation (1B20 R)
Step
Activity
1
Unscrew the air filter cap (1).
2
Remove the screws and nuts.
Figure
Remove the sound protection
hood (2).
Procedure
NOTICE
i
58
The steps described here can only be performed after the appropriate preparations have been completed.
Step
Activity
1
Remove dirt in the area of the
cylinder head cover (1).
Figure
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
2
Remove the screws (2).
Maintenance
Figure
(2 screws in 1B20, 1B27 and
1B30, 3 screws in 1B40 and
1B50).
3
Take off the cover (3) with the
gasket (4).
4
Turn the engine in the sense of
rotation until the rocker arm (1)
has fully opened the outlet
valve. Then check the tappet
clearance at the rocker arm (2)
with a feeler gauge (3). For the
setting, see the chapter 4.1
Engine, page 23.
5
Turn the engine in the sense of
rotation until the rocker arm (2)
has fully opened the intake
valve. Now check the tappet
clearance at the rocker arm
(1).
6
If the tappet clearance needs
to corrected:
Release the screw (4) and turn
the hex nut (5) so the feeler
gauge (3) can be pulled
through with a barely perceptible resistance after the screw
(4) is tightened again.
HATZ
7
Mount the cylinder head cover
with the new gasket and tighten evenly.
8
Fully assemble the engine.
Operator's Manual 1B20-1B50
59
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
9
Perform a test run. Check the
cylinder head cover for tightness.
Figure
8.2.7 Maintaining the oil bath filter
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Let the engine cool before maintenance.
CAUTION
▪
Do not repair the oil bath filter (weld/solder, etc.) as this may
lead to destruction of the filter or damage to the engine.
▪
For model with cyclone precleaner:
Never add oil to the dust trap.
Procedures
The procedure differs depending on how the engine is equipped:
▪ Procedures for oil bath filter without cyclone precleaner
▪ Procedures for oil bath filter with cyclone precleaner
Procedures for oil bath filter without cyclone precleaner
60
Step
Activity
1
Remove the oil container (1).
2
Remove the dirty oil and
sludge and clean the container.
3
Rinse the filter insert (2) in diesel fuel. Before assembling the
filter, drip or wipe dry.
4
Clean the filter housing (3) if it
is very dirty.
Figure
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
Step
Activity
5
Fully assembly the filter and
prepare it for operation by filling it with oil (see the chapter
7.8.2 Oil level in the oil bath filter (option), page 46).
Figure
Procedures for oil bath filter with cyclone precleaner
Step
Activity
1
Take off the dust collection
container (1), empty it and
clean it without using liquids.
2
Also clean the intake opening
(2) without liquids.
3
Fully assemble the cyclone
precleaner and tighten with the
wing nut.
Figure
8.2.8 Clean the cooling air area
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Let the engine cool before maintenance.
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
HATZ
▪
Wear safety goggles.
▪
Never direct the compressed air jet toward people or toward
yourself.
Operator's Manual 1B20-1B50
61
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Procedure
Step
Activity
Figure
Dry contamination
62
1
Remove the screws (1).
2
Take off the recoil start (2) and
clean it.
3
Clean the fan blades with a
suitable brush.
4
Then blow it out with compressed air.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
5
Also clean the cooling ribs of
the cylinder head (3) and cylinder (4) and blow out with compressed air.
6
Check the air gap (5) for dirt
and clean with compressed air
if necessary.
Maintenance
Figure
Note:
In 1B20 and 1B27, the air gap
(5) is markedly smaller than
the gap shown in the figure
(size approx. 5 mm).
7
The element can be checked
and cleaned through the holes
in the contact guard.
8
Mount the recoil start (2)
again.
Moist or oily contamination
1
HATZ
Contact the HATZ service station.
Operator's Manual 1B20-1B50
63
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
8.2.9 Check the screw connections
NOTICE
i
▪
Do not retighten the screws for attaching the cylinder head.
▪
The adjustment screws on the speed regulator and the injection system are secured with locking varnish and are not
permitted to be tightened or adjusted.
Procedure
Step
Activity
1
Check the condition of all
screw connections and ensure
that they are tight (exceptions,
see note).
2
Tighten any lose screw connections.
Figure
8.2.10 Clean the exhaust screen
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪
Let the engine cool before maintenance.
CAUTION
Danger of injury
There is a danger of injury when performing cleaning work at the
exhaust screen.
▪
64
Wear safety gloves.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
Procedures
The exhaust screen can be cleaned in different ways depending on how the
engine is equipped:
▪ Cleaning the exhaust screen in standard models
▪ Cleaning the exhaust screen in models for rammer operation (1B20 R)
Cleaning the exhaust screen in standard models
HATZ
Step
Activity
1
Release the hex nut and take
off the exhaust manifold (1).
2
Remove the hex nut from the
bracket (2) and pull out the
screen insert (3).
3
Remove the deposits in the
screen insert with a suitable
wire brush.
4
Check the screen insert for
cracks or breakage, and replace if necessary.
5
Mount the screen insert and
bracket again.
Figure
Operator's Manual 1B20-1B50
65
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
6
Tighten the hex nut (1) by approx. one turn.
7
Insert the exhaust manifold
with the bracket (2) into the
hole and pull it back to the outside so that the bracket can no
longer become unhooked.
8
Tighten the hex nut.
Figure
2
Clean the exhaust screen in models for rammer operation (1B20 R)
66
Step
Activity
1
Release the hex nut and take
off the exhaust manifold (1).
2
Remove the hex nut from the
bracket (2) and pull out the
screen insert (3).
Figure
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
HATZ
Step
Activity
3
Remove the deposits in the
screen insert with a suitable
wire brush.
4
Check the screen insert for
cracks or breakage, and replace if necessary.
5
Pull the hose (4) off of the exhaust manifold.
6
Check that the pipe connection
(5) is clear. Remove deposits
using a screwdriver or similar
instrument.
7
Attach the hose again.
8
Mount the screen insert and
bracket again.
Maintenance
Figure
Operator's Manual 1B20-1B50
67
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
9
Tighten the hex nut (1) by approx. one turn.
10
Insert the exhaust manifold
with the bracket (2) into the
hole and pull it back to the outside so that the bracket can no
longer become unhooked.
11
Tighten the hex nut.
Figure
2
8.2.11 Changing the fuel filter
Safety notes
DANGER
Fire hazard from fuel
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
68
▪
Do not spill fuel.
▪
No open flames when working on the fuel system.
▪
Do not smoke
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
CAUTION
Danger of injury
Repeated contact with diesel fuel can cause chapped and
cracked skin.
▪
Wear safety gloves.
CAUTION
Danger of environmental damage from spilled fuel.
When the filter is removed, a small amount of fuel is drained as
well.
▪
Collect emerging fuel and dispose of it in an environmentally
compatible manner.
CAUTION
Dirt particles can damage the injection system.
▪
Maintain clean conditions to ensure that dirt does not enter
the fuel line.
Procedures
The fuel filter can be changed in different ways depending on how the engine is equipped:
▪ Model with fuel filter in tank
▪ Model with double fuel filter system
▪ Model with external fuel filter
Model with fuel filter in tank
HATZ
Step
Activity
1
Open the fuel cap (1) and pull
the fuel filter (2) out of the tank
by the cord.
Figure
Operator's Manual 1B20-1B50
69
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
2
Pull the fuel feed line (3) off of
the fuel filter (4) and insert a
new filter.
3
Insert the fuel filter back into
the tank.
4
Close the fuel cap.
Figure
The fuel system is bled automatically.
Model with double fuel filter system
NOTICE
i
70
▪
The advantage of this system is that dirt particles that may
enter the fuel line during a filter change are captured by the
downstream outside filter and are therefore unable to endanger the injection system.
▪
This outside filter is NOT permitted to be changed. Only
change the fuel filter in the tank.
Step
Activity
1
Do not change the maintenance-free outside filter (1).
Figure
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
2
Open the fuel cap (2) and pull
the fuel filter (3) out of the tank
by the cord.
3
Pull the fuel feed line (4) off of
the fuel filter (5) and insert a
new filter.
4
Insert the fuel filter back into
the tank.
5
Close the fuel cap.
Maintenance
Figure
The fuel system is bled automatically.
Model with external fuel filter
NOTICE
i
HATZ
In the model with an external fuel filter, there is no fuel filter in
the tank.
Operator's Manual 1B20-1B50
71
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
1a
Water separator without window:
Figure
Empty the fuel tank (1). Open
the screw (2) and let the fuel
drain into a clean container.
The fuel can be used again later.
1b
Water separator with window:
Empty the fuel tank (1). Open
the screw (2) and let the fuel
drain into a clean container.
The fuel can be used again later.
2
Unscrew the fuel filter (3) from
the holder.
3
Place a suitable container under the fuel filter to collect the
remaining fuel.
4
Pull the fuel line (4) off of the
fuel filter (5) on both sides and
insert a new filter.
Observe the flow-through direction (arrows).
72
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
5
Attach the fuel filter to the
holder.
6
Fill the fuel tank with diesel
fuel (see the chapter 7.6 Refueling, page 40).
Maintenance
Figure
The fuel system is bled automatically.
7
Check the fuel filter and lines
for tightness after a brief trial
run.
8.2.12 Maintaining the dry air filter
NOTICE
i
▪
Immediately clean the filter cartridge if the maintenance display appears at maximum speed.
▪
Renew the filter cartridge after a use period of 500 operating
hours.
Procedures
The dry air filter is maintained in a series of steps that depend on how the
engine is equipped:
▪ Check the air filter maintenance indicator (additional equipment).
▪ Installing and removing the filter cartridge
Checking the air filter maintenance indicator (additional equipment)
In a dusty environment, check the rubber bellow several times a day.
HATZ
Step
Activity
1
Bring the engine briefly to
maximum speed.
Figure
Operator's Manual 1B20-1B50
73
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
2
Maintain the dry air filter when
the rubber bellow contracts
and covers the green field (1).
Figure
Installing and removing the filter cartridge
Step
Activity
1
Unscrew the air filter cover(1).
2
Unscrew the knurled nut (2)
and remove the air filter cartridge (3).
3
Clean the filter housing (4)
and cover for the air filter.
Figure
Ingress of dirt or other foreign bodies into the intake
opening (5) of the engine absolutely must be avoided.
74
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Maintenance
Step
Activity
4
In the model with an air filter
maintenance display (6),
check the condition and
cleanliness of the valve shim
(7).
5
The air filter cartridge either
needs to be replaced, or
cleaned or checked depending on the degree of contamination (see the chapter
8.2.13 Checking and cleaning the air filter cartridge,
page 75).
6
Assemble in reverse order.
Figure
8.2.13 Checking and cleaning the air filter cartridge
Safety notes
CAUTION
Danger of injury.
When working with compressed air, foreign bodies may fly into
your eyes.
▪
Wear safety goggles.
▪
Never direct the compressed air jet toward people or toward
yourself.
NOTICE
i
▪
The pressure must not exceed 5 bar.
▪
Even minor damage in the areas of the sealing surface, filter
paper or filter cartridge makes it impossible to reuse the filter cartridge.
Checking and cleaning the air filter cartridge
Step
Activity
Figure
Dry contamination
HATZ
Operator's Manual 1B20-1B50
75
Maintenance
1B20, 1B27, 1B30, 1B40, 1B50
Step
Activity
1
Blow out the filter cartridge
(1) with dry compressed air
from the inside to the outside
until dust no longer emerges.
2
Check the sealing surface
(2) of the filter cartridge for
damage.
3
Check the filter cartridge for
cracks in the filter paper and
other damage by holding it
against the light at a slant or
letting light from a lamp
shine through it.
4
Replace the filter cartridge if
necessary (see note).
Figure
Moist or oily contamination
1
76
Renew the filter cartridge.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
9
Faults
9.1
Troubleshooting
Faults
Troubleshooting notes
If the cases listed below have been worked through but the fault continues to
persist, please contact your nearest HATZ service station.
Type of fault
Possible causes
Remedy
The engine either
hesitates or does
not start at all, but
can be turned easily as usual.
Speed control lever
in stop or idle position. Stop pin in
STOP position.
Position the speed
control lever in the
"START" operating
position.
Move the stop pin
by pulling it lightly
into the operating
position.
No fuel at the injec- Add fuel. Systemtion pump.
atically check the
entire fuel supply:
If this does not
yield results:
- Check the feed
line to the engine.
Chapter
7.5.1
Switching
off the engine (mechanical),
page 37
7.6 Refueling, page 40
8.2.11
Changing
the fuel filter, page 68
- Check the fuel filter.
Insufficient compression:
▪ Wrong tappet
clearance.
At low temperatures
HATZ
Check the tappet
clearance and adjust if necessary.
▪ Cylinder and/or
piston ring wear.
Contact the HATZ
service station.
Injection nozzle is
not functional.
Contact the HATZ
service station.
8.2.6 Check
and set the
tappet
clearance,
page 56
Temperature below Activate the pre
7.4.2 Startstart limit tempera- glow unit (addition- ing the enture.
al equipment).
gine with an
electric
starter,
page 35
Operator's Manual 1B20-1B50
77
Faults
1B20, 1B27, 1B30, 1B40, 1B50
Type of fault
Possible causes
Remedy
Chapter
The machine is not If possible, sepauncoupled.
rate the engine
from the machine
by uncoupling it.
Pre glow system is Contact the HATZ
faulty (additional
service station.
equipment)
Fuel gelled due to Check whether the
insufficient cold re- fuel that emerges
sistance.
from the detached
fuel feed line directly at the injection pump is clear
and not cloudy. If
the fuel has gelled,
either warm the engine or drain the
entire fuel supply
system. Fill with a
temperature-resistance fuel mixture.
Starting speed below 400 rpm :
▪ Oil too viscous.
▪ Insufficiently
charged battery.
78
4.2 Fuel,
page 24
7.6 Refueling, page 40
8.2.11
Changing
the fuel filter, page 68
Change the engine
oil and add oil of
the right viscosity
class.
7.8 Checking the oil
level and
adding oil if
necessary,
page 44
Check the battery
and contact the
service center if
necessary.
3.2.4 Electrical equipment,
page 18
When equipped
with a stop magnet
or an automatic
electrical switch-off
mechanism (additional equipment)
The stop magnet is Contact the HATZ
not functional
service station.
and/or irregularities
in the electrical
equipment.
The engine starts
but then fails to
continue running.
The speed control
lever is not sufficiently set to the
Start direction.
Set the lever to the 7.4 Starting
Start position.
the engine,
page 32
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Type of fault
With automatic
electrical switch-off
mechanism (additional equipment)
Faults
Possible causes
Remedy
Machine is not uncoupled.
If possible, separate the engine
from the machine
by uncoupling it.
Fuel filter is clogged.
Change the fuel fil- 8.2.11
ter.
Changing
the fuel filter, page 68
Stop signal from
monitoring elements that are associated with the
automatic switchoff.
Identify the triggering monitoring element and eliminate
the source of the
fault, or contact the
HATZ service station.
Monitoring element Check the engine
for:
for:
▪ Oil pressure too
low.
Engine oil
filling level
▪ Engine tempera- Contamination of
ture too high.
the cooling air
guides or another
impairment of the
cooling system.
Faulty AC alternator.
Chapter
7.8 Checking the oil
level and
adding oil if
necessary,
page 44
8.2.8 Clean
the cooling
air area,
page 61
Contact the Hatz
service station.
Fault signal from
Check the electrithe overvoltage
cal equipment and
and polarity protec- their components.
tion system in the
voltage regulator:
3.2.4 Electrical equipment,
page 18
▪ Battery and/or
other cable connections are incorrectly connected.
▪ Loose cable connections.
HATZ
Operator's Manual 1B20-1B50
79
Faults
1B20, 1B27, 1B30, 1B40, 1B50
Type of fault
Possible causes
Remedy
Chapter
The starter does
not switch on and
the engine does
not turn.
Irregularities in the
electrical equipment:
Check the electrical equipment and
their components.
▪ Battery and/or
other cable connections are incorrectly connected.
Contact the Hatz
service station.
3.2.4 Electrical equipment,
page 18
▪ Cable connections are loose
and/or oxidized.
▪ Battery is faulty
and/or not loaded.
▪ Faulty starter.
▪ Faulty relay,
monitoring elements, etc.
Engine switches off Fuel supply is interspontaneously dur- rupted:
ing operation.
▪ The tank ran out Add fuel
of fuel during operation
▪ Fuel filter is clog- Change the fuel filged
ter.
▪ Tank vent is
clogged.
Ensure that the
tank is sufficiently
vented.
▪ Air in the fuel
system.
Check the fuel system for air ingress.
7.6 Refueling, page 40
8.2.11
Changing
the fuel filter, page 68
Check the bleed
valve.
▪ Mechanical
faults.
80
Contact the Hatz
service station.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
Type of fault
Faults
Possible causes
With automatic
Stop signal from
electrical switch-off monitoring elemechanism
ments that are associated with the
(additional equipautomatic switchment)
off.
Remedy
Identify the triggering monitoring element and eliminate
the source of the
fault, or contact the
HATZ service station.
Monitoring element Check the engine
for:
for:
▪ Oil pressure too
low.
Engine oil
filling level
▪ Engine tempera- Contamination of
ture too high.
the cooling air
guides or another
impairment of the
cooling system.
Faulty AC alternator.
Chapter
7.8 Checking the oil
level and
adding oil if
necessary,
page 44
8.2.8 Clean
the cooling
air area,
page 61
Contact the Hatz
service station.
Fault signal from
Check the electrithe overvoltage
cal equipment and
and polarity protec- their components.
tion system in the
voltage regulator:
3.2.4 Electrical equipment,
page 18
▪ Battery and/or
other cable connections are incorrectly connected.
▪ Loose cable connections.
The engine loses
power and speed.
The fuel supply is impaired
▪ The tank ran out Add fuel.
of fuel during op- Change the fuel fileration.
ter.
▪ Fuel filter is clog- Ensure that the
ged.
tank is sufficiently
▪ Tank vent is
clogged.
HATZ
vented.
Operator's Manual 1B20-1B50
7.6 Refueling, page 40
8.2.11
Changing
the fuel filter, page 68
81
Faults
1B20, 1B27, 1B30, 1B40, 1B50
Type of fault
Possible causes
Remedy
▪ Air in the fuel
system.
Check the fuel system for air ingress.
Chapter
Check the bleed
valve.
▪ The speed adBlock the speed
justment lever
adjustment.
does not stay in
the desired position.
The engine loses
power and speed,
and black smoke
emerges from the
exhaust.
Engine becomes
very hot.
Indicator lamp for
the cylinder head
temperature (additional equipment)
lights up.
Air filter is dirty.
Clean the air filter
or renew it.
8.2.12
Maintaining
the dry air
filter,
page 73
Tappet clearance
not OK.
Adjust the tappet
clearance.
8.2.6 Check
and set the
tappet
clearance,
page 56
Injection nozzle is
not functional.
Contact the Hatz
service station.
Too much engine
oil in the engine.
Drain the engine oil 7.8 Checkto the upper mark ing the oil
of the dipstick.
level and
adding oil if
necessary,
page 44
Inadequate cooling:
Clean the cooling
air area.
▪ Contamination in
the entire area of
the cooling air
guides.
▪ Incompletely
closed air baffle
plates.
82
Check the cooling
air baffle plates
and shafts for completeness and
good sealing properties.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
9.2
Faults
Type of fault
Possible causes
Remedy
Condensate
emerges from the
exhaust silencer.
Operation under no Operate the maload for an extend- chine at a load of
ed period.
approx. 70 % until
the exhaust outlet
is dry again.
Chapter
Emergency start
If an electrical fault signal occurs, the automatic switch-off locks the shutoff
valve (1) and thereby stops the fuel supply to the injection pump – the engine switches off. Also, a fault in the electrical equipment can cause the engine to switch off.
If this occurs at a critical location, such as at a railroad crossing or intersection, an emergency start can be activated.
Function of shutoff valve
Starting key settings:
Set the starting key to "I".
The shutoff valve (1) is unlocked electrically. The fuel supply is enabled, the
engine is ready to start.
Set the starting key to "0".
The shutoff valve (1) is switched off. The fuel supply is blocked and the engine switches off.
Electrical automatic shutoff (additional equipment)
The distinguishing feature of the electrical automatic shutoff is brief flashing
of all indicators after turning the starting key to position "I".
NOTICE
i
Note - If the engine stops again immediately after starting, or
stops independently during operation, this is an indication that a
monitoring element of the automatic shutoff has been activated
(see the chapter 9.1 Troubleshooting, page 77.
Safety notes
CAUTION
Danger when switching off the engine from the emergency
operation mode.
During the emergency operation mode, the engine can only be
switched off with the starting key if the emergency start lever is
first returned to its home position in a clockwise direction.
HATZ
Operator's Manual 1B20-1B50
83
Faults
1B20, 1B27, 1B30, 1B40, 1B50
CAUTION
Danger of later engine damage.
The monitoring components (oil pressure, charge control and
engine temperature) are deactivated in emergency operation.
▪
The oil level must be checked before the emergency operation phase.
NOTICE
i
If the emergency operation mode is used, the risk transfers to
the operator (the Motorenfabrik HATZ does not accept liability in this case).
▪
Immediately after the emergency operation phase, determine the cause of the fault.
▪
Have the Hatz service station supply the emergency start
lever with a new lead seal.
Overview
Pos.
Designation
1
Fuel shutoff valve (additional equipment)
2
Emergency start lever
Procedure
Step
Activity
1
Using suitable pliers, turn the emergency start lever (2) counterclockwise by at least 90° (seal wire tears).
The emergency start level is now located in the start position,
and the shutoff valve (1) is mechanically unlocked.
84
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
HATZ
Faults
Step
Activity
2
Start the engine with the electric starter or recoil start (see the
chapter 7.4.1 Starting the engine with recoil start (up to -6 °C),
page 33).
3
Turn the emergency start lever back to the stop in a clockwise
direction. Otherwise, it will not be possible to switch off the machine using the starting key.
Operator's Manual 1B20-1B50
85
Storage and disposal
1B20, 1B27, 1B30, 1B40, 1B50
10
Storage and disposal
10.1
Storing the machine
General information
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in the chapter 3 Safety,
page 7.
Storing the machine for a lengthy period
Take the following measures if you intend to take the machine out of service
for a lengthy period:
Step
Activity
1
After the machine has cooled down, cover it to protect it against
dust and store it in a dry and clean place.
The new engine can normally be stored for up to 1 year.
The protection lasts up to approx. 6 months at very high humidity and with
sea air.
If the storage time is longer, please contact the nearest Hatz service.
10.2
Disposing of the machine
Disposal information
Dispose of the machine (including machine parts, engine oil and fuel) according to the local disposal regulations and the environmental laws in the
country of use.
Because of the danger of possible environmental damage, only permit an
approved specialist company to dispose of the machine.
NOTICE
When the machine has reached the end of its lifecycle, ensure
that it is disposed of safely and properly, especially parts and
substances that can be dangerous to the environment. These also include fuel, lubricants, plastics and batteries (if present).
86
▪
Do not dispose of the battery with the household trash.
▪
Dispose of the battery at a collection point for possible recycling.
Operator's Manual 1B20-1B50
HATZ
1B20, 1B27, 1B30, 1B40, 1B50
11
Installation declaration
Installation declaration
Extended manufacturer's declaration / Declaration of Incorporation
EC Machinery Directive 98/37/EC or 2006/42/EC*)
The manufacturer: Motorenfabrik Hatz GmbH & Co.KG
Ernst-Hatz-Straße 16
D-94099 Ruhstorf a. d. Rott
hereby declares that the incomplete machine: product description: Hatz diesel engine
Type designation and as of serial number:
1B20=10031; 1B20 NON EPA=30031; 1B20V=11121; 1B20V NON EPA=30121; 1B20R=14410;
1B27=12510; 1B27 NON EPA=30810;
1B30=10125; 1B30 NON EPA=30225; 1B30V=11216; 1B30V NON EPA=30316;
1B40=11014; 1B40 NON EPA=30414; 1B40V=11714; 1B40V NON EPA=30514;
1B50=12411; 1B50 NON EPA=30611; 1B50V=12611; 1B50V NON EPA=30711
satisfies the following basic safety and health protection requirements in acc. with Annex I to the
above-mentioned Directive.
- Annex I, General principles no. 1
- Nr. 1.1.2., 1.1.3., 1.1.5., 1.2.1., 1.2.2., 1.2.3., 1.2.4.1., 1.2.4.2., 1.3.1., 1.3.2., 1.3.3., 1.3.4.,
1.3.7., 1.3.9., 1.4.1., 1.5.1., 1.5.3., 1.5.8., 1.5.9., 1.6.1., 1.6.2., 1.6.4., 1.7.
All relevant basic safety and health protection requirements down to the interfaces described
in the operating manual
in the enclosed data sheets
in the enclosed technical documents
have been complied with.
The special technical documents in acc. with Annex VII B of the Directive 2006/42/EC have been
prepared **).
Conformity with the provisions of the following, other EC Directives, i.e.
- 2004/108/EG Electromagnetic Compatibility (EMC), dated 15.12.2004
The following standards have been used (completely or partially):
- EN 1679-1: 051998
- EN ISO 12100-1: 042004
- EN ISO 13857: 062008
- EN ISO 14121-1: 122007
- EN ISO 12100-2: 042004
I will submit the above-mentioned specific technical documents electronically to the competent
government authority, if applicable**)
The Operating Manual has been enclosed to the incomplete machine and the Assembly Instructions
have been provided to the customer electronically together with the order confirmation.
Commissioning has been prohibited until it has been established, if applicable, that the machine into
which the above-mentioned incomplete machine is to be incorporated, satisfies the provisions of the
Machinery Directive.
Wolfgang Krautloher / see "Manufacturer"
Name / address of EC documentation officer **)
29/10/2009
Krautloher / Directives official
Date
Signature and information on the undersigned
Signature
*) The machine satisfies the substantial requirements of both directives
98/37/EC shall apply until 28.12.2009; 2006/42/EC shall apply as of 29.12.2009
**) applies only to the Directive 2006/42/EC
HATZ
Operator's Manual 1B20-1B50
87
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.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising