Hatz 2-4L41C Manual Download Page 90

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Maintenance

2-4L41C, 2-4M41(Z), 4L42C, 4M42

HATZ

Manual

Overview 4L42C and 4M42

Drain plug

Preparation 4L42C and 4M42

Step

Activity

Close the fuel lines on the filter housing.

Place a suitable container under the filter to collect emerging
fuel.

Release the drain screw (1) and drain the fuel.

Overview 4L42C and 4M42

Strap wrench (HATZ order no.: 620 307 01)

Gasket

Summary of Contents for 2-4L41C

Page 1: ...CREATING POWER SOLUTIONS MANUAL for diesel engine Hatz Diesel 2 4L41C 2 4M41 4L42C 4M42 www hatz diesel com ...

Page 2: ......

Page 3: ...ormation and filling quantities 21 4 2 Engine type plate 23 4 3 Physical operating conditions 24 4 4 Engine oil 24 4 5 Fuel 25 5 Engine design 27 6 Transport assembly and commissioning 33 6 1 Transport 33 6 2 Installation notes 34 6 3 Preparations for commissioning 35 6 4 Filling engine oil first filling 35 7 Operation and use 37 7 1 Safety notes 37 7 2 Performing tests 38 7 3 Start preparation 38...

Page 4: ...ns 75 8 2 9 Cleaning the screen insert in the exhaust pipe additional equipment 75 8 2 10 Changing the fuel prefilter 77 8 2 11 Maintaining the dry air filter 79 8 2 12 Checking and cleaning the air filter cartridge 81 8 2 13 Check and set the tappet clearance 83 8 2 14 Changing the oil filter 86 8 2 15 Change the main fuel filter 87 8 2 16 Checking that the air filter maintenance indicator is wor...

Page 5: ...ual rests entirely with Motorenfabrik HATZ Ruh storf This manual may only be copied or distributed if written approval has been received This also applies to the copying or distribution of excerpts of this manual The same conditions apply to distribution of this manual to third par ties in digital form Original manual This manual has been translated into multiple languages The German version is th...

Page 6: ...s The global HATZ service network is at your disposal to ad vise you and supply you with spare parts For the address of the Hatz ser vice station nearest you please see the enclosed spare parts list or visit us in the Internet at www hatz diesel com Installation of unsuitable spare parts can lead to problems We cannot ac cept responsibility for direct damage or secondary damage that results from t...

Page 7: ...king with the machine Motorenfabrik HATZ does not accept any liability for damage resulting from this The operational safety of the machine is only guaranteed if it is used as in tended Use according to the intended purpose also includes observance of the in structions in this Operator s Manual Foreseeable misuse The following is considered to be foreseeable misuse Any use that varies from or exte...

Page 8: ...HATZ service station It is prohibited to start the engine before it is fully installed In addition please note that it is prohibited to start up the machine before it has been determined that the machine into which this engine is installed ful fills all safety related requirements and legal regulations User obligations The operator is obliged to only operate the machine when it is in perfect con d...

Page 9: ...to state of the art tech nology and the recognized safety standards Despite these precautions risks exist when operating the machine and during maintenance work These risks are identified in this manual by means of safety notes The safety notes precede the related description or operating step Structure of the safety notes The safety notes consist of Danger symbol signal word Description of danger...

Page 10: ...s injury or death CAUTION This signal word is used to indicate potentially dangerous situations which if not avoided may lead to minor or moderate injury CAUTION This signal word without a danger symbol is used to indicate the risk of property damage NOTICE This signal word indicates additional useful infor mation such as operating tips and cross refer ences 3 1 4 Meaning of safety symbols Explana...

Page 11: ...osive substances Warning of toxic engine exhaust Warning of corrosive substances Warning of heavy loads Warning of environmental damage Comply with this manual or additional documentation from other manufacturers or the carrier i Additional information that is useful to the reader ...

Page 12: ... 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 Using the machine Only operate the machine for the purposes described in chapter 3 1 1 In tended use and foreseeable misuse page 7 Compliance with other regulations Adhere to the applicable accident prevention regulati...

Page 13: ... restrict the wearer s freedom of movement Warning labels and information signs on the machine The warning labels and information signs on the machine must be followed see chapter Labels 3 3 Labels page 20 The warning labels and information signs must be kept legible and must be replaced if necessary For this purpose contact your nearest HATZ service station Maintenance work Maintenance work that ...

Page 14: ...acquired in training instructional cour ses Only qualified personnel is permitted to operate and main tain this machine Failure to comply will cause the warranty to become void WARNING Danger of injury from failure to follow the operating instruc tions and from performing unauthorized tasks on the ma chine Follow all instructions Do not perform activities for which no qualification is avail able C...

Page 15: ... safety related requirements and applicable legal regulations 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 inju...

Page 16: ...ty 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 c...

Page 17: ...s an explosion hazard It is highly flammable can become electrostatically charged and can gen erate an explosive gas air mixture Use halogen free cold cleaners with a high flashpoint for cleaning Comply with manufacturer s instructions 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 injur...

Page 18: ...disconnect the negative battery terminal Never swap the positive and negative battery termi nals 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 to prevent short circuits and mass contact of current carrying cables If faults occur check the cable conne...

Page 19: ... 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 volt age peaks could destroy the electronic components When performing a manual emergency start leave the possibly depleted battery connected When cleani...

Page 20: ...ngine cooling Only run the engine when all cov ers are installed Refuel with diesel fuel only Specifi cation see the chapter 4 5 Fuel page 25 Do not use bio diesel Warning labels and information signs on the crankhandle Label Meaning 0000 038 928 01 Hold the handle bar so that it cannot twist and quickly turn the crank so that continuous traction between the engine and crank is ensured see the cha...

Page 21: ...after running in period Max 1 of fuel consumption pertaining to full load Sense of rotation When viewing flywheel left Tappet clearance at 10 30 C inlet outlet mm 0 10 Net weight M41 M41Z 4M42 L41C 4L42C Approx kg 258 263 303 308 315 363 373 388 378 433 438 Max perm inclination during continuous opera tion in direction With with out Oil sump With Oil sump Without Oil sump Only with Oil sump Operat...

Page 22: ... the dip stick 2L41C 2M41Z With Without 7 5 4 5 C A 2M41 With Without 8 5 5 5 C A 3L41C 3M41Z With Without 10 5 8 0 D A 3M41 With Without 11 0 8 5 D A 4L41C 4L42C 4M41Z With Without 13 0 D 4M41 4M42 With Without 14 0 D 2 These values are approximations only The max mark on the dipstick is decisive in any case see chapter 7 9 Check the oil level page 57 ...

Page 23: ...esignation of the engine 2 Engine serial number 3 Engine power kW at rated speed rpm 4 Displacement liters 5 Information for US emission certification EPA CARB 6 EU type approval number 7 EU country of origin Germany 8 Model year month year 9 Test specification for special settings 10 Engine family designation or exception code EM or transition code TM according to regulation EU 2016 1628 11 Addit...

Page 24: ...rated at high altitudes and high tempera tures adjustment of the engine setting may be necessary if the climatic conditions were not taken into account when the ma chine was ordered If this is the case please contact your near est HATZ service station 4 4 Engine oil Oil quality All oil brands that meet at least one of the following specifications are suit able ACEA B3 E4 or better API CF CH 4 or b...

Page 25: ...e oil that fulfills the specifications stipulated above 4 5 Fuel Fuel type All types of diesel fuel that meet the minimum requirements of the following specifications are suitable Europe EN 590 UK BS 2869 A1 A2 USA ASTM D 975 09a 1 D S15 or 2 D S15 USA ASTM D 975 09a 1 D or 2 D 1 1 Only suitable for engines without engine family designation on the en gine type plate For details see chapter 12 Decl...

Page 26: ... age to the injection system Perform the prescribed storage steps in machines that will be out of use for more than three months see section 10 1 Storing the machine page 105 Only refuel with fresh diesel fuel such as can be obtained from filling stations Winter fuel When outside temperatures drop below 0 C use winter fuel or mix in petro leum in advance Lowest ambient tempera ture at start C Perc...

Page 27: ...feed pump 2 Oil filling opening and dipstick 3 Type plate 4 Speed control lever 5 Oil filter 6 Exhaust silencer encapsulated 7 Cover for air guide housing access to cooling fan belt 8 Engine brackets 9 Oil drain screw 10 Cover plate on operating side 11 Side panel 12 Air outlet duct for cooling air 13 Capsule hood 14 Retractable lifting eye max load 5000 N ...

Page 28: ...ne with fuel prefilter 18 Fuel return line 19 Cover plate on air outlet side 20 Central connector for electrical equipment 21 Battery connections 22 Powerbox 23 Electrical maintenance switch for air filter Engine 4L42C Encapsulated model Silent Pack Pos Designation 1 Electronic control unit 2 Oil filling opening and dipstick 3 Type plate 4 Speed control lever 5 Oil filter ...

Page 29: ...panel 12 Air outlet duct for cooling air 13 Capsule hood 14 Retractable lifting eye max load 5000 N 15 Air intake duct for capsule 16 Intake opening for combustion air and cooling air 17 Fuel feed line with fuel prefilter and manual fuel pump 18 Fuel return line 19 Cover plate on air outlet side 20 Central connector for electrical equipment 21 Battery connections 22 Powerbox 23 Electrical maintena...

Page 30: ...ning for combustion air 4 Cooling fan belt 5 Cooling fan with installed three phase alternator 6 1 2 inch square socket for turning the engine 7 Oil drain screw 8 Speed control lever 9 Oil filter 10 Oil drain screw on oil sump 11 Cooling air guide for oil cooler 12 Access cap for fuel feed pump 13 Cylinder head cover 14 Air filter housing cover 15 Lifting eye max load 5000 N ...

Page 31: ... connector for electrical equipment 21 Battery connections 22 Powerbox 23 Electrical maintenance switch for air filter Engine 4M42 Standard model Pos Designation 1 Oil filling opening and dipstick 2 Side trim panel 3 Intake opening for combustion air 4 Cooling fan belt 5 Cooling fan with installed three phase alternator 6 1 2 inch square socket for turning the engine ...

Page 32: ...er 12 Fuel filter 13 Cylinder head cover 14 Air filter housing cover 15 Lifting eye max load 5000 N 16 Fuel return line 17 Fuel feed line with fuel prefilter and manual fuel pump 18 Type plate 19 Silencer 20 Central connector for electrical equipment 21 Battery connections 22 Powerbox 23 Electrical maintenance switch for air filter 24 Exhaust gas return valve EGR 25 Electronic control unit ...

Page 33: ...ine to transport it or to move it to another loca tion can lead to injuries of the back for example Only lift the machine with a hoist NOTICE Danger of environmental damage from leaking fluid If the machine is tilted engine oil and fuel can run out Only transport the machine in an upright position Transport conditions When transporting the machine follow the safety instructions When transporting f...

Page 34: ... incorrect operation of the electrical equip ment can lead to sparking and must be avoided After the engine is installed in the machine rotating parts must be pro tected against contact HATZ safety equipment is available for the belt drive of the cooling fan and alternator Comply with all notices and warning labels on the engine and keep them in a legible condition If a label should become detache...

Page 35: ... closed off or poorly ventilated rooms Do not breathe in the exhaust gases 6 4 Filling engine oil first filling Engines are normally delivered without an engine oil filling Safety notes CAUTION Danger of injury Prolonged contact with engine oil can lead to irritation of the skin Wear safety gloves If there is contact with the skin thoroughly wash the af fected areas of the skin with soap and water...

Page 36: ...l For the specification and viscosity see chapter 4 4 Engine oil page 24 The code letter on the dipstick 2 indicates whether the engine is equipped with an oil sump or not For the filling quantity see chapter 4 1 Engine information and filling quantities page 21 3 Reinsert the dipstick 4 Pull out the dipstick and check the oil level 5 If required top up the engine oil to the max mark 6 Reinsert th...

Page 37: ... from performing unauthorized tasks on the ma chine Define the responsibilities of the personnel taking the ma chine 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 o...

Page 38: ...functional condition Sliding area between crankhandle and guide sleeve lightly greased 6 No persons are located in the danger zone of the engine or ma chine 7 All safety equipment is in place 7 3 Start preparation Procedure Step Activity 1 Before the first start and with an empty fuel system Pump the fuel with the manual lever see chapter 7 3 1 Pump ing fuel with the manual lever page 38 or Pump t...

Page 39: ...mp 3 Actuate the manual lever 1 on the fuel feed pump until the fuel audibly flows back into the fuel tank through the return line 2 4 Install the access cap again 7 3 2 Pumping fuel with the manual fuel pump Requirements Pre pumping of fuel with the manual fuel pump is necessary in the following situations Engine shuts down due to empty fuel tank at first filling of the fuel tank after changing t...

Page 40: ... Step Activity 1 If there is air in the fuel system Fill with fuel if necessary 2 Place a suitable container under the filter 2 to collect emerging fuel 3 Open the bleed screw 1 by approx one turn 4 Squeeze and release the rubber ball 3 repeatedly until fuel emerges from the bleed screw 1 5 Close the bleed screw 1 and then activate the rubber ball two more times ...

Page 41: ...g options The standard equipment of the engine is an electric start mechanism A hand starter can be installed as an option If possible separate the engine from the machine being driven by uncou pling it Always switch the machine into idle mode 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...

Page 42: ...y during hand starting because the use of starting fluid can result in uncontrolled ignitions Engine damage from uncontrolled ignition Never use starting fluid 7 5 1 Starting the engine with crankhandle Only applies to engines 2 4M41 This chapter contains the following sections Preparations for cranking the engine Adjust the continuous decompression Crank the engine Crank the engine without compre...

Page 43: ...afety note CAUTION Danger of engine damage from decompression while the engine is running Do not operate the decompression lever while the engine is running Overview Decompression lever 0 Attach the crank handle Position of operator 0 3 Positions of the decompression lever 4 Guide sleeve ...

Page 44: ...linder engine 4 levers for four cylinder engine NOTICE i Only operate the decompression lever while the engine is at a standstill and observe the sense of rotation Only turn the decompression lever in the direction of the ar row Exception The lever can be turned directly back from posi tion 1 to 0 Position 1 is the continuous decompression setting Procedure Step Activity 1 Insert the crankhandle i...

Page 45: ... cautious turning where the engine starts in the opposite sense of rotation under certain circum stances smoke from the air filter release the crankhandle immediately and stop the engine To repeat the starting process wait until the engine has stopped only then recommence start preparations CAUTION Danger of injury if the crankhandle recoils or turns with the engine The use of crankhandles without...

Page 46: ...4M41 Z 4L42C 4M42 46 HATZ Manual Crank handle Attach the crank handle 1 Handle bar 2 Crank arm 3 Drive dog 4 Guide sleeve Preparation The decompression lever must be set depending on the number of cylinders of the engines 2 4M41 0 ...

Page 47: ... and the en gagement mechanism of the crank handle engage 4 Turn the crank handle forcefully with increasing speed When the decompression lever engages in the 0 position compres sion the highest possible speed must be reached 5 As soon as the engine starts pull the crank handle out of the guide sleeve NOTICE i If recoil occurs during the starting process the crank arm drive dog linkage releases vi...

Page 48: ...low display option 4 Air filter maintenance display 5 Engine temperature display option 6 Oil pressure display 7 Charge control 8 Operating display 9 Operating hours counter option Ignition lock 0 Off I Operation II Start Indicators The function of all indicators is checked when the starting key is turned They flash or light up for different times If there is a fault the applicable indi cator does...

Page 49: ...e immediately For details of trou bleshooting see section 9 1 Trouble shooting page 97 Air filter maintenance display This display lights up if the air filter is dirty Clean or replace the filter cartridge immediately For more information see chapter 8 2 11 Maintaining the dry air filter page 79 Pre glow display Lights at temperatures below 0 C Start the engine when the in dicator has gone out Pro...

Page 50: ...ap 1 from the ignition lock 3 Insert the starting key all the way and turn to position I When the pre glow display 3 lights up wait until it goes out then continue with step 4 4 Turn the starting key to position II 5 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 7 and oil pressu...

Page 51: ...ee section 7 9 Check the oil level page 57 Procedure when faults occur Step Activity 1 Check the indicators 5 7 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...

Page 52: ... If the electronics indicate a problem continuously for more than 15 minutes without interruption flash code indicator 5 the en gine switches off automatically If the problem persists the engine can be started but only for another 15 minutes If necessary contact your nearest HATZ service station 7 6 Switching off the engine Safety notes CAUTION Danger of injury from unauthorized access There is a ...

Page 53: ...cal Starting key electrical 7 6 1 Switching off the engine mechanical Overview Procedure Step Activity 1 Move the speed controller lever to the STOP position The engine switches off 2 Additional step for engines with a starter Turn the starting key to position 0 All indicator lamps go out NOTICE i Engines with an automatic switch off can also be switched off by turning the starting key back to pos...

Page 54: ...k 0 Off I Operation Procedure Step Activity 1 Turn the starting key 2 to position 0 The engine switches off All indicator lamps go out 2 Remove the starting key 3 Seal the ignition lock with the protective cap 1 NOTICE i Danger of exhaustive battery discharge When the machine is switched off always turn the starting key to position 0 or else the battery may become fully dis charged ...

Page 55: ...juries Only refuel when 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 environmental damage from spilled fuel Do not overfill the fuel tank and do not spill fuel Collect any leaking fuel and dispose of it according to local environmental regulations CAUTION Engine damage from using low qualit...

Page 56: ...c cording to local environmental regulations 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 collects at the lowest point of the fuel filter in the water sep arator 1 Drain plug 2 Bleed screw Procedure Step A...

Page 57: ...with the local environmental regulations NOTICE i Note If starting difficulties occur Bleed the injection system with the aid of the manual fuel pump with the aid of the injection system see chapter 7 3 2 1 Require ments page 39 7 9 Check the oil level Safety notes CAUTION Danger of burns There is a danger of burns when working on a hot engine Wear safety gloves CAUTION Danger of injury Prolonged ...

Page 58: ...pstick 2 Code letter on the dipstick Procedure Checking oil level adding oil Step Activity 1 Switch off the engine and wait several minutes for the engine oil to collect in the crankcase Engine must be level 2 Remove contamination on the engine in the area of the dipstick 1 3 Pull out the dipstick and clean it 4 Reinsert the dipstick 5 Pull out the dipstick and check the oil level 6 If the oil lev...

Page 59: ...ossible Always wear personal protection equipment Only use fully functional tools Installation of unsuitable spare parts can lead to problems We cannot ac cept responsibility for direct damage or secondary damage that results from this We therefore recommend the use of Hatz original spare parts Closely adhere to the maintenance conditions prescribed in this manual Only make changes to the machine ...

Page 60: ...d and described in the maintenance documentation please contact your nearest HATZ service station 8 2 Maintenance work Safety note CAUTION Danger of injury if maintenance instructions are not fol lowed Only perform maintenance when the engine is switched off Protect start up devices crank handle recoil start or start ing key from unauthorized access For engines with a starter Disconnect the negati...

Page 61: ... Z 4L42C 4M42 Maintenance HATZ 61 Manual 2M41 Without oil sump 2M31 2M40 2M41 500h 250h 1h max OIL 0 1 mm 0 004 max 2M41 With oil sump 3 4M41 and 4M42 in general M31 M40 M41 M42 500h 250h 1h max OIL 0 1 mm 0 004 max ...

Page 62: ...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 The degree of contamination of the fuel the care with which refueling is per formed and the soiling on the inside of the fuel tank are decisive in determin ing the change inter...

Page 63: ... 56 250h Every 250 operat ing hours Change the engine oil 2M41 without oil sump 2 4L41C and 4L42C in general 8 2 5 Change the en gine oil page 68 Check the poly v belt 8 2 6 Checking the poly v belt page 70 Clean the cooling fan cooling fins and oil cooler 8 2 7 Cleaning the cool ing fan cooling fins and oil cooler page 72 Check the screw connections 8 2 8 Checking the screw connections page 75 Cl...

Page 64: ...il filter 8 2 14 Changing the oil filter page 86 Every 1000 oper ating hours Change the main fuel filter 8 2 15 Change the main fuel filter page 87 Every 2000 oper ating hours Renew the gaskets in the belt tensioner or the complete belt tensioner To be carried out by a trained specialist Renew the poly v belt 8 2 17 Renewing the poly v belt and checking the function of the switch off unit page 93 ...

Page 65: ...and 4M42 3 2 4L41C and 4L42C 1 Intake opening for combustion air 2 Dust outlet opening 3 Cyclone option Procedure Step Activity 1 Check the intake opening 1 for coarse contamination such as leaves heavy dust deposits etc and clean if necessary 2 Check that the dust outlet opening 2 at the bottom of the cy clone precleaner is clear 3 If the dirt contamination is oily remover the cyclone 3 and clean...

Page 66: ...ATZ Manual Electrical air filter maintenance display 2 4L41C and 2 4M41 4L42C and 4M42 5 Air filter service indicator Mechanical air filter maintenance display 1 Red field Procedure Step Activity For the electrical air filter maintenance display ...

Page 67: ...le red field 1 in the mechanical air filter maintenance dis play The visible red field 1 indicates that maintenance work is re quired on the air filter see the chapter 8 2 11 Maintaining the dry air filter page 79 8 2 4 Checking 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 ...

Page 68: ...s heavy dust deposits etc and clean if necessary see chapter 8 2 7 Cleaning the cooling fan cooling fins and oil cooler page 72 8 2 5 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 envi ronmental regulations NOTICE i The ...

Page 69: ... 1 Unscrew the oil drain screw 1 and drain the oil entirely When unscrewing the oil drain screw 1 on engines of type 2 4L41C and 4L42C ensure that the drain pipe 2 is not loos ened Hold it with an open end wrench 2 Screw in the cleaned oil drain screw 1 with the new gasket and tighten Overview 1 Dipstick 2 Code letter on the dipstick ...

Page 70: ...t test run check the oil level and correct it if neces sary see the chapter 7 9 Check the oil level page 57 8 2 6 Checking the poly v belt 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 Damage from inadequate engine cooling Only operate the engine when all covers are installed Preparation Step Activity 1 O...

Page 71: ...belt tensioner is oily contact HATZ service 2 Check the poly v belt 2 for the following damage Transverse cracks on the rear of the belt Fraying on the side Accumulation of dirt between the ribs Oily dirt contamination Transverse cracks in multiple ribs Broken ribs If one or more of these instances of damage are present re place the poly v belt see chapter 8 2 17 Renewing the poly v belt and check...

Page 72: ...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 CAUTION Danger of engine damage from overheating The engine temperature display option lights up as soon as the engine becomes impermissibly hot Switch off the eng...

Page 73: ...ter 8 2 2 Maintenance plan page 62 Overview Preparatory activities 1 Baffle plate Preparation Cleaning Step Activity 1 On encapsulated engines unscrew the following see chapter 5 Engine design page 27 Hood Side panel Cover plate on operating side Air outlet duct for cooling air Cover plate on air outlet side 1 Remove the following on engines without a capsule Side trim panel Cooling air guide for ...

Page 74: ...ncapsulated engines also clean the area between the floor plate and crankcase 5 Mount the capsule and air guide parts again Cleaning of wet or oily dirt contamination 1 Disconnect the negative battery terminal 2 Manually clean the alternator and regulator 3 Cover the alternator with the installed regulator and do not spray directly 4 Spray the entire area with a suitable cleaning solution accord i...

Page 75: ...n system are secured with locking varnish and are not permitted to be tightened or adjusted Only retighten loose screw connections Screw connections can be secured with thread locking adhesive or tightened to a defined torque Retightening tight screw connections can cause damage Procedure Step Activity 1 Check the condition of all screw connections and ensure that they are tight for exceptions see...

Page 76: ...engine for a lengthy period without a load or with only a small load can result in premature deposits on the screen insert Shorten the maintenance interval accordingly Overview 1 Pipe clamp 2 Screen insert Procedure Step Activity 1 Release the pipe clamp 1 and remove it with the exhaust pipe 2 Remove deposits on the screen insert 2 3 Check the screen insert for cracks or breakage and replace if ne...

Page 77: ...nition Do not smoke Do not spill fuel 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 any escaping fuel and dispose of it according to lo cal environmental regulations CAUTION Dirt particles can damage...

Page 78: ... Insert a new fuel prefilter Note the following Arrow for flow direction Position of the fuel tank HIGH or LOW Installation position flow through direction should be as verti cal as possible 6 Open the fuel feed line 2 4L41C and 2 4M41 7 To simplify the starting procedure it is recommended that you pre pump the fuel using the manual lever at the fuel feed pump until you hear fuel flow back through...

Page 79: ... pump page 39 8 2 11 Maintaining the dry air filter NOTICE i Clean the filter cartridge immediately if at maximum speed the combined indicator on the instrument box flashes 14 times The air filter cartridge either needs to be replaced or cleaned or checked depending on the degree of contamina tion Renew the filter cartridge after a use period of 500 operating hours Four cylinder engines have two f...

Page 80: ...s of dirt and other foreign bodies 5 On three cylinder engines open the clamp 7 On three cylinder engines the cover 2 is additionally held by a clamp 7 6 Open the air filter housing 4 7 Take out the filter cartridge 3 8 Clean the air filter housing 4 and cover 2 9 Renew the bushing 6 if the spacer 5 is loose The spacer 5 is connected with the screw 1 by the elastic bushing 6 to ensure that it cann...

Page 81: ...ushing 6 if the spacer 5 is loose The spacer 5 is connected with the screw 3 by the elastic bushing 6 to ensure that it cannot fall into the intake pipe during disassembly and assembly 8 2 12 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 ...

Page 82: ...ide until dust no longer emerges 2 Check the sealing surfaces 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 Moist or oily contamination 1 Renew the filter cartridge Mechanical air filter mai...

Page 83: ...ck the visible red field 1 in the maintenance display by pressing the reset button 2 8 2 13 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 CAUTION Damage from inadequate engine cooling Only operate the engine when all covers are installed O...

Page 84: ...uired extension 1 into the square opening NOTICE i Turn the engine in the sense of rotation Anti clockwise in both cases flywheel side or timing cover side Numbering of the valves and cylinders from the fan side 1 2 3 4 1 2 3 4 5 6 7 8 Setting method for two cylinder engine Step Activity 1 Set the valve of the 1st cylinder fan side to overlap outlet valve not yet closed intake valve begins to open...

Page 85: ...xagon nut 2 Adjusting screw 3 Feeler gage Procedure Adjusting the tappet clearance Step Activity 1 Check the tappet clearance with the feeler gauge 3 For the setting see the chapter 4 Technical data page 21 2 If the tappet clearance needs to be corrected Release the hex nut 1 Turn the adjustment screw 2 so the feeler gauge 3 can be pulled through with a barely perceptible resistance after the hex ...

Page 86: ...OTE Under no circumstances is the engine permitted to be oper ated if not all covers are mounted 6 After a brief trial run check the cylinder head cover for tight ness 8 2 14 Changing the oil filter Safety note 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 loca...

Page 87: ...the max mark on the dipstick For the specification and viscosity see chapter 4 4 Engine oil page 25 The mark on the dipstick indicates whether the engine is equipped with an oil sump or not see chapter 4 1 Engine in formation and filling quantities page 22 7 Reinsert the dipstick 8 Check the oil level after a short test run and correct if necessary 9 Check the oil filter for tightness and retighte...

Page 88: ...nvironmental damage from spilled fuel When the filter is removed a small amount of fuel is drained as well Collect any escaping fuel and dispose of it according to lo cal environmental regulations CAUTION Dirt particles can damage the injection system Maintain clean conditions to ensure dirt does not enter the fuel line Overview 2 4L41C and 2 4M41 1 Strap wrench HATZ order no 620 307 01 ...

Page 89: ...e old filter in accordance with local environmental regulations 6 Lightly oil the gasket of the new fuel filter 7 Mount the fuel filter and tighten it by hand 8 Open the fuel feed line 9 To simplify the starting procedure it is recommended that you pre pump the fuel using the manual lever at the fuel feed pump until you hear fuel flow back through the return line into the fuel tank see the chapter...

Page 90: ...ain plug Preparation 4L42C and 4M42 Step Activity 1 Close the fuel lines on the filter housing 2 Place a suitable container under the filter to collect emerging fuel 3 Release the drain screw 1 and drain the fuel Overview 4L42C and 4M42 1 Strap wrench HATZ order no 620 307 01 2 Gasket ...

Page 91: ...w fuel filter 4 Mount the fuel filter and tighten it by hand 5 Open the fuel feed line 6 Bleed the injection system with the aid of the manual fuel pump see the chapter 7 3 2 Pumping fuel with the manual fuel pump page 39 7 After a brief trial run check the fuel filter for leak tightness and retighten by hand 8 2 16 Checking that the air filter maintenance indicator is working properly Overview El...

Page 92: ...rocedure Step Activity 1 Remove the capsule hood or side trim panel see chapter 5 En gine design page 27 2 Turn the starting key to position I 3 Pull the hose 3 off of the exhaust manifold Electrical air filter maintenance display NOTE On engine types 4L42 and 4M42 this function test cannot be performed 4 Generate a vacuum by sucking forcefully at the hose end The indicator 4 lights up ...

Page 93: ...unction of the switch off unit NOTICE i When changing the belt Always check the function of the switch off unit The switch off pin must emerge by spring force or else the machine will not switch off automatically if the belt tears If the grooves are broken off or bent renew the damaged pulley To be absolutely sure that you order the right poly v belt in terms of the length it is recommended that y...

Page 94: ...g the poly v belt Step Activity 1 Unscrew one cylinder screw 1 from the pulley 3 2 Push back the tension pulley 2 and lock it using the cylinder screw 1 3 Unscrew the pulley 3 4 Check the pulley 3 for broken or bent grooves 5 Remove the poly v belt Overview Checking the function of the switch off unit of the belt monitor ing system 1 Tension pulley ...

Page 95: ...ring pressure The angle lever 2 turns downward and releases the switch off pin 3 The switch off pin 3 must emerge by spring force or else the machine will not switch off automatically if the belt tears 2 If there is no reaction please contact the nearest HATZ service station Overview Mounting the poly v belt 1 Switch off pin 2 Tension pulley 3 Housing Procedure Mounting the poly v belt Step Activi...

Page 96: ...the pulley 1 Cylinder screw 2 Square opening Procedure Centering the pulley Step Activity 1 Lightly secure the pulley with a cylinder screw 1 without plac ing the pulley fully on the centering 2 Insert the ratchet or T piece 1 2 with the required extension into the square opening 2 3 Turn the pulley until a further cylinder screw can be fitted 4 Insert the remaining cylinder screws and tighten all...

Page 97: ...position 7 4 Setting the speed control page 41 No fuel at the injection pump Refuel 7 7 Refueling page 55 Activate the manual lever or manual fuel pump 7 3 Start prepara tion page 38 Systematically check the entire fuel supply If this does not yield results Check the feed line to the engine Check the fuel prefilter 8 2 10 Changing the fuel prefilter page 77 Check the main fuel filter 8 2 15 Change...

Page 98: ...TZ Service Fuel gelled due to in sufficient cold resis tance Check whether the fuel that emerges from the fuel feed line is clear and not cloudy If the fuel has gelled either thaw the engine or drain the entire fuel supply system Fill with a tem perature resistant fuel mixture 4 5 Fuel page 25 8 2 10 Changing the fuel prefilter page 77 8 2 15 Change the main fuel fil ter page 87 Oil is too viscous...

Page 99: ...itched off Possible causes Remedy Chapter The speed control lever is not sufficiently set in the Start direc tion Set the lever to the Start posi tion 7 4 Setting the speed control page 41 Machine is not uncou pled If possible separate the engine from the machine by uncou pling it Fuel prefilter is clogged Change the fuel prefilter 8 2 10 Changing the fuel prefilter page 77 Main fuel filter is clo...

Page 100: ... 2 15 Change the main fuel fil ter page 87 Poly v belt torn Renew the poly v belt 8 2 17 Renewing the poly v belt and checking the function of the switch off unit page 93 Mechanical faults Contact Hatz service The indicator lamp for the exhaust gas return system EGR flashes only on 4L42 and 4M42 Air filter is dirty Check the degree of dirt con tamination of the air filter and clean or renew it if ...

Page 101: ...al equipment page 18 Faulty three phase alternator Faulty relay The engine loses power and speed Possible causes Remedy Chapter The speed adjustment lever does not stay in the desired position Block the speed adjustment The fuel supply is impaired The tank ran out of fuel during operation Add fuel 7 7 Refueling page 55 Fuel prefilter or main fuel filter is clogged Change the fuel filter 8 2 10 Cha...

Page 102: ...ire area of the cooling air guides Clean the cooling air area 8 2 7 Cleaning the cooling fan cooling fins and oil cooler page 72 Incompletely closed air guide parts or capsule parts Check the air guide parts and shafts for completeness and good sealing properties 9 2 Emergency start Automatic electrical shutoff option The identifying feature of the electrical automatic shutoff is brief flashing of...

Page 103: ...g 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 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 opera tion phase NOTICE i If the emerg...

Page 104: ...e emer gency start lever 2 and tear the seal wire 3 between the emergency start lever and the housing screw with a forceful jerk 4 Turn the emergency start lever to the start position 5 Start the engine see chapter 7 5 Starting the engine page 41 6 Eliminate the emergency situation within a few seconds 7 Switch off the engine 8 Immediately after the emergency operation phase Determine and remedy t...

Page 105: ...he exhaust gases DANGER Fire hazard from fuel Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries Only refuel when 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 environmental damage from spilled fuel Do not overfill the fuel tank and do not spill fuel Collec...

Page 106: ...he main fuel filter page 87 4 Let the machine cool down 5 Remove the battery in accordance with the machine operators manual and store at ambient temperature Comply with the local regulations as well as the regulations of the battery manufac turer for the storage of batteries 6 Close and seal all engine openings air intake openings air out let openings and the exhaust gas opening so that no foreig...

Page 107: ...ice 10 2 Disposing of the machine Disposal information Dispose of the machine including machine parts engine oil and fuel ac cording 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...

Page 108: ... 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 2014 30 EU Electromagnetic Compatibility EMC dated 26 02 2014 was tested in association with a generating set The following standards ha...

Page 109: ...er The following Manufacturer s declaration of compliance with regulation EU 2016 1628 only applies to engines with an engine family designation in ac cordance with section 1 5 see next page The corresponding engine family designation is noted on the engine type plate see chapter 4 2 Engine type plate page 23 ...

Page 110: ...of the Council of 14 September 2016 on requirements relating to gaseous and particulate pollutant emission limits and type approval for internal combustion engines for non road mobile machinery amending Regulations EU No 1024 2012 and EU No 167 2013 and amending and repealing Directive 97 68 EC OJ L 252 16 9 2016 p 53 2 Commission Delegated Regulation EU 2017 654 of 19 December 2016 supplementing ...

Page 111: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 112: ...TIONS 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 0000 433 402 12 09 2018 3 Printed in Germany EN ...

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