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Maintenance

2G40, 2G40 H

HATZ

Operator’s Manual

Procedure — Adjusting the tappet clearance

Step

Activity

Check the tappet clearance with the feeler gage (5). For the set-
ting, see chapter

4.1 Engine information and filling quantities,

page 20

If the tappet clearance needs to be corrected:

▪ Release the hex nut (6).

▪ Turn the adjustment screw (7) so the feeler gage (5) can be

pulled through with barely perceptible resistance after the hex
nut (6) is tightened again.

Repeat the above procedure for the entire valve area, taking
special care to use the adjustment method described.

Mount the cylinder head cover with the new gasket and tighten
evenly.

After a brief trial run, check the cylinder head cover for tight-
ness.

8.2.8

Cleaning the cooling air area

Safety notes

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 gen-
erate an explosive gas/air mixture.

▪

Use halogen-free, cold cleaners with a high flashpoint for
cleaning.

▪

Comply with manufacturer's instructions.

CAUTION

Danger of environmental pollution due to oil and cleaning
agents.

Oil and cleaning agents are hazardous to the environment.

▪

Do no allow them to enter the ground water, water bodies,
or sewage system.

▪

Only clean the machine at the washing area intended for
this.

Summary of Contents for 2G40

Page 1: ...el engine Hatz Diesel 2G40 2G40 H www HATZ DIESEL com INCLUDESSUPPLEMENTALINFORMATIONTO THEOWNER SMANUALFORMODELYEAR2017 EPACERTIFIEDNONROADCOMPRESSION IG NITIONENGINES INCLUDESSUPPLEMENTALINFORMATIONFOR THEUSEOFEPACERTIFIEDENGINESWITHIN CALIFORNIA ...

Page 2: ......

Page 3: ...ine information and filling quantities 20 4 2 Engine type plate 21 4 3 Physical operating conditions 22 4 4 Engine oil 22 4 5 Fuel 23 5 Engine overview 25 5 1 Designation of components 25 6 Transport assembly and commissioning 27 6 1 Transport 27 6 2 Installation notes 28 6 3 Preparations for commissioning 29 6 4 Filling engine oil first filling 29 6 5 Filling the oil bath air filter option 31 7 O...

Page 4: ... 53 8 2 4 Checking the cooling air area 55 8 2 5 Change the engine oil and oil filter 56 8 2 6 Cleaning the oil bath air filter 60 8 2 7 Checking and setting the tappet clearance 62 8 2 8 Cleaning the cooling air area 64 8 2 9 Checking the screw connections 67 8 2 10 Changing the fuel filter 67 8 2 11 Maintaining the dry air filter 69 9 Faults 72 9 1 Trouble shooting 72 10 Storage and disposal 77 ...

Page 5: ...l 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 the ...

Page 6: ...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 this We theref...

Page 7: ...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 The intended use also includes observance of the instructions in this Opera tor s Manual to preserve the environment including in the appendix for the model year 2017 as per EPA Nonroad Diesel Engines Foreseeable misuse The following is considered to be forese...

Page 8: ...n engine that is not yet installed in a machine it is imperative that you follow the Assembly Instructions for HATZ Diesel Engines be fore installing the engine These assembly instructions contain important in formation on how to safely install the engine and are available at your near est HATZ service station It is prohibited to start the engine before it is fully installed In addition please not...

Page 9: ... this manual This 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 accessi ble 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 tech nology and the recognized safety standards Despite these precautions risks exist when opera...

Page 10: ...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 Explanati...

Page 11: ...ive 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: ...fety 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 regulations...

Page 13: ...estrict 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 19 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 go...

Page 14: ...uired 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 Cont...

Page 15: ...afety 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 injury...

Page 16: ...rrect engine exhaust quality 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 HAT...

Page 17: ...jury from compressed air and dust particles Eye injuries may occur when cleaning with compressed air Wear safety goggles 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 negative battery...

Page 18: ...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 connections for good con tact DANGER Danger of explosion from flammable substances There is a danger of explosion from flammable gases Keep batteries away from open flames and incendiary sparks Do not smok...

Page 19: ...eaner 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 regu lator 3 3 Labels Warning labels and information signs on the engine Label Meaning 2G40 1h max OIL OIL 0 1 mm 0 004 max 0000 040 096 02 500h 250h Maintenance instructions see chap t...

Page 20: ...ption pertaining to full load Engine oil pressure Min 1 0 bar at 900 rpm Sense of rotation on power take off side Left Tappet clearance at 10 30 C inlet outlet mm 0 10 Max perm continuous sloping position in the di rection without oil sump with oil sump Exhaust low Exhaust high Flywheel low Flywheel high 30 2 17 2 25 2 25 2 30 2 17 2 30 2 25 2 Weight Approx kg 106 Battery capacity Min max 12 V 45 ...

Page 21: ...ction pump effective stroke mm and engine capacity 8 Information on exhaust control system 9 variable speed or constant speed only if necessary The type plate also defines the applicable emissions related performance class of the engine The figure shows an EPA CARB type plate A text that refers to the exhaust legislation and corresponds to the engine type is printed on the type plate EPA or EPA an...

Page 22: ...ke air temperature C 25 K 298 Relative humidity 30 Air pressure at approx 100 meters above sea level kPa 100 NOTICE i If the machine is operated 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 Engin...

Page 23: ...nsuitable engine oil Unsuitable engine oil considerably reduces engine service life Only use engine 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 ASTM D 975 09a 1 D or 2 D CAUTION Danger of engine damage from low quality fuel The use of ...

Page 24: ...ge 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 77 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 Percent...

Page 25: ...nents Overview 1 Fuel line feed pump injection pump 2 Air guide panel 3 Dipstick 4 Fuel return line 5 Injector 6 Lifting eye 7 Starter 8 Air guide 9 Air intake pipe 10 Type plate 11 Glow plug option 12 Oil bath air filter 13 Oil pressure switch 14 Rain cap 15 Oil filler plug 16 Fuel pressure tube ...

Page 26: ...ust manifold 20 Injection pump 21 Stop lever 22 Speed control lever 23 Fuel feed pump 24 Oil filter 25 Oil drain screw 26 Protective grid 27 Air guide housing 28 Plug connection 29 Voltage controller 30 Engine mount 31 Crankshaft power take off pto 32 Fuel line fuel filter feed pump 33 Fuel filter ...

Page 27: ... hoist with a sufficient carrying capacity Do not remain under suspended loads CAUTION Only use the lifting eye for transporting the engine Do not use for lifting the entire machine CAUTION Danger of injury from overloading the body Lifting the machine 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...

Page 28: ...ce life Therefore they are usually installed in machines that are used for commer cial purposes The machine manufacturer must follow the applicable regulations regarding machine safety the engine is a part of a machine 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 t...

Page 29: ...you have any questions please contact your nearest HATZ service sta tion 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 ...

Page 30: ...s Overview 1 2 1 Dipstick 2 Oil filler plug 3 Oil refilling container Procedure Step Activity 1 Pull out the dipstick 1 and clean it 2 Unscrew the oil filler plug 2 3 Fill engine oil For the specification and viscosity see chapter 4 4 Engine oil page 22 See chapter 4 1 Engine information and filling quantities page 20 for the engine oil capacity 4 Reinsert the dipstick 5 Pull out the dipstick and ...

Page 31: ...ening on the cyclone precleaner option Procedure Step Activity 1 Release the clamp fasteners 1 2 Remove the oil container 2 3 Fill the oil container with engine oil up to the level mark 4 4 Mount the oil container ensuring that the gasket 3 is properly positioned and the clamp fasteners 1 are correctly fastened 5 When the cyclone precleaner is attached ensure that the dust outlet opening 5 is prop...

Page 32: ...king 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 or at very low load for an ex tended period can impair the running characteristics of the en gine Ma...

Page 33: ... 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 chapter 7 7 Refueling page 46 4 There is a sufficient amount of engine oil in the engine housing see chapter 6 4 Filling engine oil first filling page 29 5 Fill the oil bath air filter option with engine oil see chapter 6 5 Filling the oil bath air filter option ...

Page 34: ...the speed control page 35 7 3 1 Pumping fuel with the manual lever Requirements Pre pumping of fuel with the manual lever of the fuel feed pump is necessary in the following situations Engine shuts down due to empty fuel tank At first filling of the fuel tank After changing the fuel filter Overview 1 Manual lever 2 Fuel feed pump Procedure Step Activity 1 Fill with fuel if necessary 2 Actuate the ...

Page 35: ...1 Speed control lever 2 Stop lever Procedure Step Activity 1 Depending on the situation place the speed control lever 1 in either the 1 2 or Start position 2 Ensure that the stop lever 2 is in the START operat ing position NOTICE i A lower speed setting will cause less exhaust smoke when start ing ...

Page 36: ...machine in closed off or poorly ventilated rooms Do not breathe in the exhaust gases CAUTION Danger of engine damage from the use of starting fluid Engine damage from the use of starting fluid can lead to un controlled ignition Engine damage from uncontrolled ignition Never use starting fluid Overview HATZ instrument boxes 0 I II 1 Protective cap 2 Starting key 3 Pre glow display option 4 Air filt...

Page 37: ...circuit The battery is no longer charged Eliminate the fault immediately Oil pressure display Engine oil pressure too low Danger of engine damage Stop the engine immediately and check the oil level see section 7 6 Check the oil level page 43 Contact HATZ Service if the oil level is correct Engine temperature display Engine temperature is impermissibly high Danger of engine damage Switch off the en...

Page 38: ...ot detect at the ignition lock if the engine is still running or is already at a standstill In models equipped with a starter protection module the starting key must be kept in the 0 position for at least 8 sec onds before another start is possible after the engine is switched off Step Activity 1 Check the speed adjustment see chapter 7 3 2 Setting the speed control page 35 2 Remove the protective...

Page 39: ...he automatic shutoff has been acti vated Remedy the fault before making further starting attempts see chapter 9 1 Trouble shooting page 72 Despite the automatic switch off check the oil level every 8 15 operating hours see chapter 7 6 Check the oil level page 43 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...

Page 40: ...against dirt and moisture With the starting key pulled out seal the ignition lock with the protective cap Methods of switching off the engine The engine can be switched off in different ways depending on how it is equipped Speed control lever mechanical Stop lever mechanical Starting key electrical 7 5 1 Switching off the engine mechanical NOTICE i Engines with a blocked lower idle speed cannot be...

Page 41: ...on The engine switches off Stop lever 1 Actuate the stop lever 2 in the STOP direction and hold until the engine has stopped 2 Release the stop lever 2 The stop lever is placed automati cally in the START position by a spring NOTICE i Engines with a stop magnet can not be switched off by actuating the stop lever rather only with the starting key see chapter 7 5 2 Switching off the engine electrica...

Page 42: ...ation and use 2G40 2G40 H 42 HATZ Operator s Manual 7 5 2 Switching off the engine electrical Overview I STOP START 1 Protective cap 2 Starting key 3 Stop lever 4 Stop magnet Ignition lock 0 Off I Operation ...

Page 43: ...OTICE 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 7 6 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 contact with engine oil can lead to irritation of the ski...

Page 44: ...l filler plug 3 Oil refilling container 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 ...

Page 45: ... oil container 2 3 Check for dirt When the deposited dirt has reached approximately half the height of the oil filling or the oil has become viscous clean the oil bath air filter see chapter 8 2 6 Cleaning the oil bath air filter page 60 4 Otherwise check the oil level and fill with engine oil up to the level mark 4 as required 5 Mount the oil container ensuring that the gasket 3 is properly posit...

Page 46: ...ion 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 quality fuel The use of fuel that does not meet the specifications can lead to engine damage Only use the fuel specified in chapter...

Page 47: ... 4 Manual lever Procedure Step Activity 1 Open the fuel cap 2 2 Fill the fuel tank with diesel fuel 3 Close the fuel cap 4 Proceed as follows when the fuel system is empty Pre pump with the manual lever 4 on the fuel feed pump 3 until the fuel audibly flows back through the return line into the fuel tank ...

Page 48: ... display 1 Air filter service indicator 2 Red field 3 Reset button Procedure Step Activity 1 Bring the engine briefly to maximum speed 2 If depending on the version the air filter service display 1 lights or the red field 2 is locked check the air filter system im mediately see chapter 8 2 11 Maintaining the dry air filter page 69 3 Check the air filter service display several times a day ...

Page 49: ...lace faulty machine parts as soon as possible 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 ma...

Page 50: ...t 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 maintenance instructions are not fol lowed Only perform maintenance when the engine is switched off Protect the starting key against unauthorized access Disconnect the negative terminal of the batt...

Page 51: ...earance and adjust if necessary Checking 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 The interval at which maintenance work should be performed on the fuel fil ter depends on the cleanliness of the fuel in use and ma...

Page 52: ...ilter 7 6 2 Oil level in the oil bath air fil ter option page 45 250h Every 250 operat ing hours Change the engine oil and oil filter 8 2 5 Change the engine oil and oil filter page 56 Clean the oil bath air filter 8 2 6 Cleaning the oil bath air fil ter page 60 Check and set the tappet clearance 8 2 7 Checking and setting the tappet clearance page 62 Clean the cooling air area 8 2 8 Cleaning the ...

Page 53: ...r Safety notes CAUTION Danger of burns There is a danger of burns when working on a hot engine Let the engine cool before maintenance NOTICE i In case of heavy contamination shorten the maintenance inter vals accordingly see chapter 8 2 2 Maintenance plan page 51 Oil bath air filter Overview 1 Intake opening for combustion air 2 Dust outlet opening on the cyclone precleaner option ...

Page 54: ...low and clean if neces sary see chapter 8 2 6 Cleaning the oil bath air filter page 60 Dry air filter Overview 1 Intake opening for combustion air 2 Dust discharge valve 3 Air intake hose 4 Hose clamps 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 discharge valve 2 is clear Remove du...

Page 55: ...maintenance 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 engine immediately and eliminate the cause NOTICE i In case of heavy contamination shorten the maintenance inter vals accordingly see chapter 8 2 2 Maintenance plan page 51 Overview 1 Intake opening for cooling air 2 Coolant air...

Page 56: ...oncluding the inspection work 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 CAUTION Danger of environmental damage from spilled used oil Used oil is water polluting Do no allow it to enter the ground water water bodies or sewage system Collect the used oil and dispose of it according to local envi r...

Page 57: ...er of later engine damage 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 engine must be horizontal and have been switched off for a few minutes NOTICE i The engine must be level The engine must be switched off Only drain engine oil while it is warm Draining the engine oil Overview Version without oil sump Ve...

Page 58: ...For the engine oil filling quantity see section 4 1 En gine information and filling quantities page 20 2 Unscrew the oil drain screw 1 and drain the oil entirely 3 Screw in the cleaned oil drain screw 1 with the new gasket 2 and tighten Tightening torque see chapter 4 1 Engine information and fill ing quantities page 20 Changing the oil filter Overview 1 2 1 Strap wrench 2 Screen plate 3 Sealing s...

Page 59: ...ulations 4 Lift the screen plate 2 off the oil overpressure valve with a screwdriver The sealing surface 3 must not be damaged when doing this 5 Blow out the screen plate 2 from the inside with compressed air and then press back onto the oil overpressure valve 6 Thoroughly clean the sealing surface 3 7 Lightly oil the sealing lip 4 of the new oil filter 5 8 Screw in the oil filter and tighten it b...

Page 60: ...insert the dipstick 8 Screw in the oil filler plug Concluding the inspection work Step Activity 1 Check the oil level after a short test run and correct if necessary 2 Check the oil filter for tightness and retighten by hand if neces sary 8 2 6 Cleaning the oil bath air filter Safety notes CAUTION Danger of burns There is a danger of burns when working on a hot engine Let the engine cool before ma...

Page 61: ...fected areas of the skin with soap and water CAUTION Danger of injury Repeated contact with diesel fuel can cause chapped and cracked skin Wear safety gloves CAUTION Danger of engine damage due to a damaged oil bath air fil ter Do not repair the oil bath air filter weld solder etc as this may lead to destruction of the filter or damage to the engine Overview 1 Oil container 2 Rain cap 3 Cyclone pr...

Page 62: ...ling the filter allow to thoroughly drip off or wipe off the diesel fuel 8 Check the filter housing before mounting If the sealing surface is uneven or there are cracks in the filter housing or filter wool is missing do not use the filter rather replace it by a new filter 9 Install the filter housing using a new gasket package 9 10 Fully assemble the filter and prepare it for operation by filling ...

Page 63: ...ket 4 and seal rings 2 Adjustment method Cylinder 1 flywheel side clockwise sense of rotation Cylinder 2 power take off side counter clockwise sense of rotation Step Activity 1 Turn the engine in the sense of rotation until the valves of the 2nd cylinder start to overlap outlet valve not yet closed intake valve begins to open 2 Turn the crankshaft by 180 in the sense of rotation and check the valv...

Page 64: ...4 Mount the cylinder head cover with the new gasket and tighten evenly 5 After a brief trial run check the cylinder head cover for tight ness 8 2 8 Cleaning the cooling air area Safety notes 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 gen erate an explosive gas air mixture...

Page 65: ...people or toward yourself CAUTION Danger of damage to the machine from incorrect engine cleaning Let the engine fully cool down before cleaning Do not spray components of the electrical equipment with a water jet or high pressure jet during cleaning Do not use gasoline or acid based cleaning agents CAUTION Damage from inadequate engine cooling Only operate the engine when all covers are installed ...

Page 66: ...essed air Moist or oily contamination 1 Disconnect the negative battery terminal 2 Spray the entire area with a suitable cleaning solution according to manufacturer instructions and then clean off with a jet of wa ter Do not spray components of the electrical equipment with a wa ter jet or high pressure jet during cleaning 3 Blow dry the engine with compressed air 4 Determine the cause of the oil ...

Page 67: ...ng 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 note 2 Tighten any lose screw connections 8 2 10 Changing the fuel filter Safety notes DANGER Fire hazard from fuel Leaked or spilled fuel can ignite on hot engine parts and cause ...

Page 68: ... to ensure dirt does not enter the fuel line Overview 1 Fuel feed line 2 Fuel filter Procedure Step Activity 1 Lock the fuel feed line before and after the fuel filter 2 Place a suitable container under the fuel filter to collect emerg ing fuel 3 Pull the fuel line 1 off the fuel filter 2 on both sides and insert a new filter Observe the flow through direction arrows 4 Release the fuel feed and pr...

Page 69: ...safety gloves 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 Immediately clean the filter cartridge if the maintenance dis play appears at maximum speed Renew the filter cartridge after a use period of 500 operating hours Overview 1 Rain cap ...

Page 70: ... collar nut 5 5 Carefully pull out the filter cartridge 6 6 Damage in the filter area 6 and in the area of the sealing lip 7 preclude further use 7 Pull the guide apparatus 8 out of the filter housing 9 8 Clean all parts excluding the filter cartridge Ingress of dirt or other foreign bodies into the intake opening of the engine must be strictly avoided Procedure Checking and cleaning the air filte...

Page 71: ... 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 Procedure Mounting the air filter cartridge Step Activity 1 When assembling mount the parts individually one after the other to make sure they are correctly seated...

Page 72: ... speed control page 35 Stop lever in STOP po sition Set the lever to the START operating position 7 5 1 Switching off the engine mechanical page 40 No fuel at the injection pump Refuel 7 7 Refueling page 46 Actuate the fuel feed pump option Systematically check the entire fuel supply If this does not yield results Check the feed line to the engine Check the fuel filter 8 2 10 Changing the fuel fil...

Page 73: ...scous and causes a too low starter speed Change the engine oil Add engine oil with a suitable viscosity class 8 2 5 Change the engine oil and oil filter page 56 Insufficiently charged battery Check the battery and contact the service center if necessary 3 2 4 Electrical equipment page 18 Machine is not uncou pled If possible separate the engine from the machine by uncou pling it The starter does n...

Page 74: ...ch off mechanism optional No oil pressure Check the oil level 7 6 Check the oil level page 43 Faults in the AC al ternator or alternator charging circuit Contact Hatz Service Engine temperature too high Check the cooling air guides for contamination or other im pairments 8 2 8 Cleaning the cooling air area page 64 Fault signal from the overvoltage and polarity protection system in the voltage regu...

Page 75: ...oltage and polarity protection system in the voltage regulator Battery and or other cable connections are incorrectly connected Check the electrical equipment and its components or contact Hatz service 3 2 4 Electrical equipment page 18 Loose cable connec tions The engine loses power and speed Possible causes Remedy Chapter The speed adjustment lever does not stay in the desired position Block the...

Page 76: ...arance 8 2 7 Checking and setting the tappet clearance page 62 Injection nozzle not OK Contact HATZ Service Engine becomes very hot Indicator lamp for engine temperature option lights up Possible causes Remedy Chapter Too much engine oil in the engine Drain the engine oil to the up per mark of the dipstick 7 6 Check the oil level page 43 Inadequate cooling Contamination in the entire area of the c...

Page 77: ...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 Collect a...

Page 78: ...l as the regulations of the battery manufacturer 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 foreign bodies can enter but a small amount of air can still be ex changed This avoids condensation 7 After the machine has cooled down cover it to protect it against dust and store it in a dry and clean p...

Page 79: ... 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 pre...

Page 80: ...nterfaces described in the manual for diesel engine 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 The following standards have been used completely or partially EN 1679 1 092011 EN ISO 12100 032011 EN ISO 13857 062008 EN 60204 1 062007 The manual for dies...

Page 81: ... s Manual 12 EPA CERTIFIED ENGINES SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR MODEL YEAR 2017 EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION RELATED INSTALLATION INSTRUCTIONS ...

Page 82: ...y for engine operation The following parts as manufactured according to HATZ specifications are mandatory for engine operation which meets EPA exhaust emission regula tions Fuel Injection pump Injection nozzle Extra fuel device Crankcase breather valve assembly Air cleaner housing Intake manifold Exhaust manifold Oil filler cap Intake and exhaust gaskets at head interfaces Emission Control Informa...

Page 83: ... 3 000 hours and 3 000 hours intervals thereafter Fuel 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 work shop Hatz authorised workshops for example are qualified workshops Hatz Diesel of America will give you respective addresses if requ...

Page 84: ...e lack of re ceipts or for your failure to ensure the performance of all scheduled main tenance 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 modifica tions You are responsible for presenting your engine to a Motorenfabrik Hatz authorized service cent...

Page 85: ...ny other parts directly caused by failure of such replacement parts This warranty does not obligate Hatz to bear any transportation charges in connection with the repair or replacement of defective parts 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...

Page 86: ...stall the engine in a way that makes the engine s emission control information labels hard to read during normal engine maintenance you must place duplicate labels on the equipment EQUIPMENT LABELLING REQUIREMENTS FUEL LABEL see chapter 3 3 Labels page 19 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 additiona...

Page 87: ...regulation requirements 2G40 2G40 H Exhaust silencers and protection guard The exhaust silencer is fitted in connection with spring washers Fixation is done by Allen screws Dismantling Remove in numerical sequence 1 4 Assembly Assemble in reverse sequence Apply lubricant as specified by HATZ Ensure gasket kit is fitted in correct sequence i e the creased gaskets 4 face towards exhaust silencer Use...

Page 88: ...ing the exhaust sample with ambient air as follows Version 1 Specification 1 Adding a 20 centimeter linear extension to the exhaust pipe Engine type Ø d mm Version 1 HATZ Ident Nr Clamp HATZ Ident Nr 2G40 2G40H 40 0000 830 582 00 0000 503 398 00 Version 2 Specification 2 Adding a 20 centimeter bended extension to the exhaust pipe Engine type Ø d mm Version 2 HATZ Ident Nr Clamp HATZ Ident Nr 2G40 ...

Page 89: ...H EPA CERTIFIED ENGINES WITHIN CALIFORNIA HATZ 89 Operator s Manual 13 EPA CERTIFIED ENGINES WITHIN CALIFORNIA SUPPLEMENTAL INFORMATION TO THE OWNER S MANUAL FOR THE USE OF EPA CERTIFIED ENGINES WITHIN CALIFORNIA ...

Page 90: ...b pages for in use off road diesel vehicles http www arb ca gov msprog ordiesel ordiesel htm requirements Below is a description of applications for determining preempted equipment Please also see information regarding the federal non road engine emis sions control program http www epa gov nonroad The following preemption list has been modified At the request of industry staff has removed the term...

Page 91: ...Farm loaders front end Skid steer loaders Feed conveyors Specialized fruit nut harvester Fertilizer spreader Sprayers bituminous concrete curing crop field Forage box Haulage and loading machine Stump cutters grinders Forklifts diesel and or rough ter rain Stumpbeater Harvesters crop Surfacing equipment Jackhammer Swathers Light towers Tampers and rammers Mixers mortar plaster grout Tractor compac...

Page 92: ... CALIFORNIA 2G40 2G40 H 92 HATZ Operator s Manual 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 93: ......

Page 94: ... 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 433 315 13 10 2017 0 1 Printed in Germany USA EPA IV ...

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