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Hatz Diesel 2G 40 H, Instruction Book

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INSTRUCTION BOOK

2G40
2G40 H

33

433 316 05-USA-EPA IV-CARB

12.07-0.05

Printed in Germany

INCLUDES SUPPLEMENT

AL INFORMA

TION T

O THE 

OWNER’S MANUAL

FOR 2008 

AND LA

TER EP

A CERTIFIED

NONROAD COMPRESSION-IGNITION ENGINES

INCLUDES SUPPLEMENT

AL INFORMA

TION T

O THE 

OWNER’S MANUAL

FOR 2008 

AND LA

TER CALIFORNIA

REGULA

TIONS FOR HEA

VY-DUTY

OFF-ROAD ENGINES

Summary of Contents for 2G 40 H

Page 1: ...nted in Germany INCLUDES SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES INCLUDES SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY DUTY OFF ROAD ENGINES ...

Page 2: ...in order to ensure long lasting reliable performance Please follow all maintenance references carefully including the schedule for 2008 and later EPA certified nonroad compression ignition engines or for 2008 and later California certified Heavy Duty off road engines to prevent our environment Please pass this Instruction Manual on to the next user or to the following engine owner The worldwide HA...

Page 3: ...every 500 hours of operation 21 6 Functional test 23 6 1 Air filter maintenance indicators 23 7 Malfunctions Causes Remedies 24 8 Work on the electrical system 27 9 Protective treatment 27 SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES 29 SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR 2008 MODEL YEAR AND LATER CALIFORNIA REG...

Page 4: ... cooled down after being stopped Faulty wiring or incorrect operation of electrical equipment may lead to sparks forming and must be avoided as a potential fire hazard Rotating parts must be shielded against accidental contact when the engine is installed in other equipment or machinery Guards are available from HATZ to protect belt drives to cooling fans and generators Before attempting to start ...

Page 5: ...bracelets or any other things which you could get caught with Please pay attention to all advice and warning stickers placed on the engine and keep them in legi ble condition Contact your next HATZ Servicestation if a sticker comes off or is illegible and ask for a new one Note that any unauthorized modification to the engine absolves its manufacturer from liability for the consequences Regular se...

Page 6: ... 12 Oilbath air cleaner 13 Oil pressure switch 14 Rainproof cap 15 Oil filler cap 16 Fuel pressure pipe 17 Cylinder head cover 18 Engine oil line 19 Exhaust manifold 20 Fuel injection pump 21 Stop lever 22 Speed control lever 23 Fuel feed pump 24 Engine oil filter 25 Oil drain plug 26 Guard 27 Air guide housing 28 Separable connector 29 Voltage regulator 30 Engine mount 31 Crankshaft power take of...

Page 7: ... in period approx 1 of fuel consumption at full load Direction of rotation power take off end anti clockwise Valve clearances at 10 30 C Inlet exhaust mm 0 10 Max permissible perm inclination Exhaust Flywheel Angle of inclination in low high low high without oil sump 30 2 17 2 25 2 25 2 with oil sump 30 2 17 2 30 2 25 2 Weight incl fuel tank air cleaner kg exhaust silencer and electric starter app...

Page 8: ...all the information you need if your engine has not yet been installed on or in the equipment it is intended to drive or set up in its correct operating position You can obtain a copy of this manual from your nearest HATZ service station 3 The permitted loads and elements on the speed adjusting lever and the stop lever should be observed as an exess can lead to damage to the contacts and inner gov...

Page 9: ...n For any offer as well as spare parts orders it is necessary to mention the following data also see spare parts list page 1 engine type spec only for special equipment engine number max engine rated speed The layout is identical for constant speed and variable speed application Attention If the engine was certified for constant speed application and shall be used so the field con stant speed only...

Page 10: ...ONLY 4 Operation 4 1 Before initial start up Engines are normally delivered without fuel and oil 4 1 1 Engine oil Oil quality Qualified are all trademark oils which fulfil at least one of the following specifications ACEA B2 E2 or more significant API CD CE CF CF 4 CG 4 or more significant If engine oil of a poorer quality is used reduce oil change intervals to 150 hours of operation Oil viscosity...

Page 11: ...ust trap is fitted make sure that the dust outlet is pointing in the correct direction fig 7 Fill the oil tank up to mark 1 with engine oil Attach oil tank 2 making sure that sealing ring 3 is correctly seated and clips 4 are fastened securely 4 1 3 Fuel 8 Stop the engine before refuelling Never add fuel near a naked flame or a source of sparks Don t smoke Use only pure fuel and clean filling equi...

Page 12: ...o 30 50 4 2 Starting the engine Do not run the engine in closed or badly ventilated rooms danger of poisoning Before starting the engine make sure that no one is within the danger area near the engine or the machinery it is driving and that all the necessary guards are installed 4 2 1 Preparations for starting If possible disengage the engine from any driven equipment The auxiliary equipment shoul...

Page 13: ...igh Switch off the engine and trace and elimi nate the cause of the problem see chapter 7 The air cleaner maintenance indicator 5 additional equipment only lights up during operation if the air cleaner element needs to be cleaned or renewed see Chapter 5 4 2 Always turn the start key back to position 0 before re starting the engine The repeat lock in the ignition lock prevents the starter motor fr...

Page 14: ...sure that it returns to its original START position Start Run Stop Start Stop 14 The charge 2 and oil pressure pilot lamps 3 come on Turn the ignition key to the 0 position and pull it out The pilot lamp lights must then go out Note Engines with an automatic electrical shutdown system can also be stopped by turning the igni tion key back to positon 0 During breaks in operation or at the end of the...

Page 15: ...tc replaced in their correct positions Before starting the engine make sure that no one is in the danger area engine or driven machinery Every 8 15 operating hours or before daily starting Check oil level Check area around combustion air input Check cooling air system Check that the oil level in the lower part of the oil bath air cleaner is correct and that the oil is not contaminated 5 2 1 5 2 2 ...

Page 16: ...ervals For new or reconditioned engines the following must always be carried out after the first 25 operating hours Replace engine oil and oil filter chap 5 3 2 Check tappet clearance and adjust if necess ary chap 5 3 3 Examine screw connections chap 5 3 5 For short operating periods replace engine oil and oil filter after 12 months at the latest regardless of the number of operating hours 15 ...

Page 17: ...n creased dust accumulation necessitates a corre spondingly shorter maintenance interval Chapter 5 3 1 and 5 4 2 With oilbath air cleaner 16 Inspect air inlets 1 depending on version for severe dirt and dust deposits and clean if necessary Make sure that dust outlet 2 on the cyclone type dust trap depending on version is not obstructed and clean if necessary chap 5 3 1 With dry type air cleaner 17...

Page 18: ...aves dust accumulation etc clean if necessary fig 19 chap 5 3 4 The temperature indicator 1 if installed will light up as soon as the engine becomes too hot Shut down the engine immediately 5 3 Maintenance work every 250 operating hours 5 3 1 Maintenance work on oilbath air cleaner 20 Take off oil tank 1 and clean it Take off rain cap 2 or cyclone type dust trap 3 and clean Clean right through int...

Page 19: ... Re assemble the remaining parts of the air cleaner and fill with oil to prepare for further operation chap 4 1 2 5 3 2 Engine oil change and oil filter renewal The engine must be stopped and in a horizontal position Drain the engine oil only when the engine is warm Danger of scalding from hot oil Trap the old oil and dispose of it in accordance with local legislation 22 23 Take out drain plug 1 a...

Page 20: ...en 1 from the inside by blowing through with compressed air After cleaning press the mesh screen back on to the oil pressure relief valve Never re use the throwaway filter element 1 G3 28 2 26 Clean sealing face 1 thoroughly Oil sealing ring 2 on the new filter element lightly Screw in throwaway filter element 3 handtight Add engine oil chap 4 1 1 Run the engine briefly to check that there are no ...

Page 21: ... grees check valve clearances for cylinder 2 and adjust if necessary Adjusting Measure valve clearance with 0 10 mm feeler gauge 5 fig 27 chapt 3 1 If adjustment is necessary slacken off hex nut 6 turn adjusting screw 7 and retighten nut 6 It should then be possible to pull feeler gauge 5 through with just perceptible resist ance to movement fig 27 Replace the cover in position and tighten it down...

Page 22: ...ws at the engine governor and on the injection system are sealed with lacquer or with lead and are not to be tightened or adjusted 5 4 Maintenance work every 500 hours of operation 5 4 1 Renew the fuel filter The maintenance intervals for the fuel filter are dependent upon the purity of the diesel oil being used and if necessary may have to be reduced to 250 hours When working on the fuel system d...

Page 23: ...mage to the filter 6 or in the area of the lip seal 7 Pull guide 8 out of filter housing 9 Clean all parts except the filter element Do not spray into the engine air intake Cleaning the filter cartridge Dry contamination 32 Using a compressed air pistol with a bent tube insert blow through the cartridge from the in side with dry compressed air moving up and down until no more dust is emitted Impor...

Page 24: ...nce switch with powerful suction indicator lamp 1 must light up fig 33 If there is no reaction check cable connectors and replace filament lamp and or maintenance switch if necessary For mechanical indicator Unscrew maintenance indicator 3 fig 33 Create a vacuum at the maintenance indicator with powerful suction the visible red area must latch in replace maintenance indicator if necessary Before p...

Page 25: ...l flocculent due to inade quate cold stability Move the lever in START posi tion Fill up with fuel Check the complete fuel supply system systematically If no re sult check fuel supply line to the engine fuel filter function of the feed pump Check valve clearances adjust if necessary See workshop manual See workshop manual See workshop manual Operate glow plug equipment additional equipment Disenga...

Page 26: ...elays monitoring elements etc Speed control lever not located far enough in the start direction Device not disengaged Fuel filter blocked Fuel supply interrupted Fuel supply interrupted Tank run dry Fuel filter blocked Fuel feed pump defective Mechanical malfunctions Replace and fill up with oil Check the battery if necessary contact a service station Check the electical system and its components ...

Page 27: ...required position Air filter contaminated Incorrect valve clearances Injector jets unserviceable Too much oil in the engine Inadequate cooling Contamination in the entire area for the air guides Insufficiently enclosed air guides Fill up with fuel Replace fuel filter Ensure adequate ventilation of the tank Check the line screw connec tions for leaks Block the speed control Clean air filter Adjust ...

Page 28: ...Never disconnect the battery while the engine is running Electric voltage peaks can cause damage to electrical components When cleaning the engine do not spray elec trical components with water If this is un avoidable first disconnect the battery Dry all components carefully with compressed air be fore reconnecting them When carrying out welding work on the en gine or attached equipment attach the...

Page 29: ......

Page 30: ...TAL INFORMATION TO THE OWNER S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION RELATED INSTALLATION INSTRUCTIONS 29 ...

Page 31: ... engine operating conditions Maintenance instructions for EPA related engine parts Emission control system and adjustments Warranty statement Emission related installation instructions ENGINE PARTS AND OR EQUIPMENT RELATED TO EPA EXHAUST EMISSION REGULATIONS Parts which are mandatory for engine operation The following parts as manufactured according to HATZ specifications are mandatory for engine ...

Page 32: ...e nearest HATZ authorized Service Center for necessary repairs The engine is designed and adjusted to operate most efficiently at the following conditions Air temperature of 25 C 77 F Atmospheric pressure of 100 kPa 14 5 psi Relative humidity of 30 Operation of the engine at conditions other than above will affect performance and exhaust emissions Normally the equipment manufacturer takes this int...

Page 33: ...l injector The exhaust quality of the engines can be influenced by the execution the quality of execution of above described maintenance work Therefore the maintenance work has to be carried out by a qualified workshop Hatz authorised workshops for example are qualified workshops Hatz Diesel of America will give you respective addresses if required EMISSION CONTROL SYSTEM AND ADJUSTMENTS The emiss...

Page 34: ...per maintenance of your engine Your emission control system includes Fuel injection pump Injection nozzle s Extra fuel device Crankcase breather valve assembly Air cleaner housing Intake manifold Exhaust manifold Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Information Labels Where a warrantable condition exists Motorenfabrik Hatz will repair your engine at no cost...

Page 35: ... cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should be aware however that Motorenfabrik Hatz may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a Motorenfab...

Page 36: ...ers 2008 and later EPA certified engines and applies to the following exhaust emission related components Fuel injection pump Injection nozzle s Extra fuel device Crankcase breather valve assembly Air cleaner housing Intake manifold Exhaust manifold Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Information Labels 35 ...

Page 37: ...rts This warranty is transferrable to subsequent owners only under the named warranty coverage conditions In order to obtain service under this warranty the retail purchaser should contact Hatz Diesel of America Inc at 262 544 0254 for information and the nearest service center The retail purchaser will not be charged for diagnostic labor which leads to the determination that a warranted part is d...

Page 38: ...ngine maintenance you must place duplicate labels on the equipment EQUIPMENT LABELLING REQUIREMENTS FUEL LABEL Chapter 3 5 The fuel label has to be permanently attached to the equipment In case of an engine mounted fuel tank every engine is equipped with an additional fuel label Otherwise there are two loose fuel labels available with the engine If the original fuel label is not readily visible af...

Page 39: ...ns to properly install the exhaust system and related components consistent with the EPA emission regulation requirements Exhaust silencers and protection guard The exhaust silencer is fitted in connection with studs flat washers and hex nuts Fixation is done by Allen screws J 38 2G40 ...

Page 40: ...s Remove silencer 4 and gaskets 5 and 6 Assembly Assemble in reverse sequence Apply lubricant as specified by HATZ Ensure gasket kit is fitted in correct sequence i e the creased gaskets 5 face towards exhaust silencer Assemble protection guard if so fitted in reverse sequence 3 1 Use anti seize compound J as specified by HATZ 39 ...

Page 41: ...d in the equipment and placed in service the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample with ambient air as follows Specification 1 Adding a 20 centimeter linear extension to the exhaust pipe 40 Version 1 ...

Page 42: ...ation 2 Adding a 20 centimeter bended extension to the exhaust pipe 41 Version 2 Engine type Ø d mm Version 1 HATZ Ident Nr Version 2 HATZ Ident Nr Clamp HATZ Ident Nr 2G40 H 40 830 582 00 830 853 00 503 398 00 ...

Page 43: ......

Page 44: ...NTAL INFORMATION TO THE OWNER S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY DUTY OFF ROAD ENGINES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT AND EMISSION RELATED INSTALLATION INSTRUCTIONS 43 ...

Page 45: ...aintenance instructions for CARB related engine parts Emission control system and adjustments Warranty statement Emission related installation instructions ENGINE PARTS AND OR EQUIPMENT RELATED TO CARB EXHAUST EMISSION REGULATIONS Parts which are mandatory for engine operation The following parts as manufactured according to HATZ specifications are mandatory for engine operation which meets CARB e...

Page 46: ...of 25 C 77 F Atmospheric pressure of 100 kPa 14 5 psi Relative humidity of 30 Operation of the engine at conditions other than above will affect performance and exhaust emissions Normally the equipment manufacturer takes this into account during the design of the machine and your equipment will perform within specifications over a wide range of climatic conditions However if you must operate your ...

Page 47: ...orenfabrik Hatz GmbH Co KG are pleased to explain the emission control system warranty on your 2008 and later engine In California new heavy duty off road engines must be designed built and equipped to meet the State s stringent anti smog standards The Motorenfabrik Hatz GmbH Co KG must warrant the emission control system on your engine for the periods of time listed below provided there has been ...

Page 48: ...f all scheduled maintenance As the heavy duty off road engine owner you should however be aware that Motorenfabrik Hatz GmbH Co KG may deny you warranty coverage if your heavy duty off road engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on low sulfur diesel fuel or ultra low sulfur diesel fuel only Use of any oth...

Page 49: ... standard HATZ DIESEL LIMITED ENGINE WARRANTY and covers 2008 and later California certified Heavy Duty off road engines and applies to the following exhaust emission related components Fuel injector s Fuel injection pump Cold start device Intake manifold Exhaust manifold Crankcase breather valve Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Information Labels 48 ...

Page 50: ...arranty is transferrable to sub sequent owners within the original twenty four 24 months time period In order to obtain service under this warranty the retail purchaser should contact Hatz Diesel of America Inc at 262 544 0254 for information and the nearest service center The retail purchaser will not be charged for diagnostic labor which leads to the determination that a warranted part is defect...

Page 51: ...ngine maintenance you must place duplicate labels on the equipment EQUIPMENT LABELLING REQUIREMENTS FUEL LABEL Chapter 3 5 The fuel label has to be permanently attached to the equipment In case of an engine mounted fuel tank every engine is equipped with an additional fuel label Otherwise there are two loose fuel labels available with the engine If the original fuel label is not readily visible af...

Page 52: ...ns to properly install the exhaust system and related components consistent with the EPA emission regulation requirements Exhaust silencers and protection guard The exhaust silencer is fitted in connection with studs flat washers and hex nuts Fixation is done by Allen screws 51 J 2G40 ...

Page 53: ...s Remove silencer 4 and gaskets 5 and 6 Assembly Assemble in reverse sequence Apply lubricant as specified by HATZ Ensure gasket kit is fitted in correct sequence i e the creased gaskets 5 face towards exhaust silencer Assemble protection guard if so fitted in reverse sequence 3 1 Use anti seize compound J as specified by HATZ 52 ...

Page 54: ...d in the equipment and placed in service the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample with ambient air as follows Specification 1 Adding a 20 centimeter linear extension to the exhaust pipe 53 Version 1 ...

Page 55: ...ation 2 Adding a 20 centimeter bended extension to the exhaust pipe 54 Version 2 Engine type Ø d mm Version 1 HATZ Ident Nr Version 2 HATZ Ident Nr Clamp HATZ Ident Nr 2G40 H 40 830 582 00 830 853 00 503 398 00 ...

Page 56: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

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