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MAINTENANCE AND WARRANTY.

SUPPLEMENTAL INFORMATION TO THE OWNERS MANUAL FOR 2008 AND
LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES.

The following supplemental information is furnished for EPA Nonroad Compression
Ignition Engines which are certified according to 40 CFR Part 89 and Part 1039.

This information contains the following specific items:

• EPA-related engine parts and engine operating conditions

• Maintenance instructions for EPA-related engine parts

• Emission control system and adjustments

• Warranty statement

• Emission-related installation instructions

ENGINE PARTS AND / OR EQUIPMENT RELATED TO EPA EXHAUST
EMISSION REGULATIONS.

Parts which are mandatory for engine operation.

The following parts as manufactured according to HATZ specifications are mandatory for
engine operation which meets EPA exhaust emission regulations.

• Air cleaner housing

• Cold air duct

• Turbocharger ( including wastegate ), ducting

• Unit Injectors

• Oil filler cap

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Summary of Contents for 2W35

Page 1: ...NCLUDES 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...

Page 2: ...ntenance intervals 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 i...

Page 3: ......

Page 4: ...Check water trap 26 5 3 3 Clean the radiator fins 27 5 3 4 Check screw connections 28 5 3 5 Check the Vee belt 28 5 4 Maintenance every 500 operating hours 29 5 4 1 Replace primary fuel filter 29 5 4...

Page 5: ...contact with rotating parts once the engine is connected to the driven equipment or machine HATZ protective guards are available for the belt drive of the cooling fan and alternator drive systems Alwa...

Page 6: ...le the engine is warm risk of scalding The cooling system is pressurized Wear close fitting clothing only when working on the engine while it is running Please don t wear necklaces bracelets or any ot...

Page 7: ...plate 3 Coolant pump 4 Oil dipstick 5 Oil filler cap 6 Drain plug for coolant 7 Oil drain plug governor side 8 Engine mountings optional equipment 9 Oil drain plug operator s side 10 Engine oil filte...

Page 8: ...lug for electrical system 8 Oil drain plug exhaust side 9 Voltage regulator 10 Fan optional equipment 11 Radiator optional equipment 12 Coolant supply to engine 13 Coolant return to radiator and therm...

Page 9: ...ptional equipment 6 Hydraulic pump drive optional equipment 7 Flange for additional hydraulic pump optional equipment 8 Oil drain plug governor side 9 Engine mountings optional equipment 10 Oil drain...

Page 10: ...aust flange 6 Electric starter 7 Oil drain plug exhaust side 8 Central plug for electrical system 9 Voltage regulator 10 Coolant supply to engine 11 Coolant return to radiator and thermostat 12 Temper...

Page 11: ...ox 2 5 1 3 4 1 4 4 1 4 4 1 Difference between max and min levels l approx 1 2 1 1 4 1 1 6 1 1 6 1 Lubricating oil consumption after running in approx 0 5 of fuel consumption at full load Lubricating o...

Page 12: ...es contains 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 t...

Page 13: ...average person For any offer as well as spare parts orders it is necessary to mention the following data also see spare parts list page 1 engine type spec only for special equipment engine number max...

Page 14: ...UR FUEL ONLY 4 Operation 4 1 Before initial start up The engines are normally delivered to the cus tomers without fuel oil and coolant filling Important When replenishing liquids it is essential that...

Page 15: ...p and pull it out again Read the oil level on the dipstick if necessary add oil until the level reaches the max mark Attention If the engine is operated while the oil level is be low the min mark it w...

Page 16: ...kin contact must be avoided Comply with the manufacturer s instructions Add water to the coolant before pouring it in the cooling circulation Clean water which is not excessively hard must be used for...

Page 17: ...ion tank Tighten cap 1 by hand After the engine has warmed up check coolant level again When the engine is at a standstill and has cooled down the coolant level must be visible between the tank s MIN...

Page 18: ...r while the primary fuel filter or the fuel filter are replaced To bleed the system proceed as described be low depending on whether the fuel tank is arranged in HIGH position above the fuel supply pu...

Page 19: ...e engine as described in Chapter 4 2 Models with electrical supply pump With this model first turn the starter key to position I and wait for approx one minute Chapter 4 2 2 During this waiting time t...

Page 20: ...attempts Should the engine fail to start even at the 2nd attempt locate and eliminate the trouble Chapter 6 19 Insert the key to its stop and turn it to position I Battery charge pilot lamp 2 and oil...

Page 21: ...t start the engine without delay Automatic electrical shutdown system optional equipment This is characterized by a brief flashing of all pilot lamps once the starter key has been turned to position I...

Page 22: ...onal equipment 21 Press the stop lever down towards STOP and hold it until the engine has come to a stand still When the engine is not running any longer release stop lever The stop lever is returned...

Page 23: ...15 operating hours or before each daily start up Check oil level Check combustion air intake area Check air cleaner maintenance indicator Check radiator fins for contamination Check coolant level 5 2...

Page 24: ...e subject to maintenance chart shown in this chapter For new or reconditioned engines the following must always be carried out after first 50 operat ing hours Replace engine oil and oil filter Chap 5...

Page 25: ...it out again Check the dipstick oil level and if necessary add oil to the max mark Chapter 4 1 1 Attention If the engine is operated while the oil level is below the min mark it will be damaged 5 2 2...

Page 26: ...the pilot lamp 5 to go on When it does go on check the dry air cleaner Chapter 5 4 3 5 2 4 Check radiator fins for contamination Serious contamination means that the mainte nance intervals must be sh...

Page 27: ...the cooling system via the cap on the expansion tank This may be due to contamination in the radiator fin area Chapter 5 2 4 or to engine overload Add coolant refer to Chapter 4 1 2 5 3 Maintenance ev...

Page 28: ...ine must be at a standstill and have cooled down Important The delicate radiator fins must never be cleaned using tools such as a screw driver or a spatula Deformed radiator fins or radiator leakage m...

Page 29: ...are sealed with lacquer and are not to be tightened or adjusted Figs 35 and 36 5 3 5 Check the Vee belt optional equipment Check the Vee belt over its entire circumference for cracks or damage if nec...

Page 30: ...rating hours 5 4 1 Replace primary fuel filter Note Primary fuel filter maintenance intervals depend on the purity of the fuel used in the engine and should be reduced to 250 hours if necessary Do not...

Page 31: ...nd be at a standstill Danger of scalding from hot oil Trap the old oil and dispose of it in accordance with local legislation Horizontal replaceable cartridge filter standard equipment 41 Release repl...

Page 32: ...tighten it by hand Assemble the air filter cartridges and the cover for the air cleaner Chapter 5 4 3 Replenish lubricant of the appropriate specifi cation and viscosity until the level reaches the M...

Page 33: ...nter the engine air intake port 1 49 Check seal 1 and rubber pad 2 for damage de formation and cracks if necessary replace The filter cartridge must either be replaced or depending on the degree of co...

Page 34: ...ning a light source through it Important The slightest damage to the paper filter rules out its being used any longer Re assemble the filter cartridge in the reverse order of work 51 Make sure the fil...

Page 35: ...me near the fuel system when work ing on it Important Maximum cleanliness is required to prevent dirt from entering the fuel system Fuel particles may damage the injection system Replace the fuel filt...

Page 36: ...fluid is used a replacement interval of 2 or 4 years is envisaged The various products are charac terized by their identification colour For further explanations refer to Chapter 4 1 2 Work on the co...

Page 37: ...he engine and drain coolant 60 Subsequently unscrew the drain plug 1 from the radiator and drain the coolant as well Turn in drain plugs 1 with new packing ring 2 and tighten them Fig 59 and 60 Fill t...

Page 38: ...tional equipment Fuel highly viscous due to inadequate resistance to low temperatures Set lever to START position Add fuel Bleed the injection system Check entire fuel supply system carefully If no fa...

Page 39: ...rrupted One of the automatic shutdown s monitoring elements has initiated a stop signal See also Chapter 6 4 Fault in the electrical system Battery and or other cables incorrectly connected Cable conn...

Page 40: ...incorrectly connected Cable connections loose Fuel supply interrupted Tank has run empty Primary fuel filter or fuel filter clogged Tank insufficiently ventilated Pipe connections leaky Speed control...

Page 41: ...icient cooling effect Radiator fins soiled Loss of coolant Vee belt broken or slack only in case of models with belt driven fan Engine overloaded Clean or renew the air cleaner See workshop manual See...

Page 42: ...failed pilot lamp without delay Do not remove the starter key while the engine is running Do not disconnect the battery while the en gine is running Electric voltage peaks can cause damage to electron...

Page 43: ......

Page 44: ...AL 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 INSTRU...

Page 45: ...parts and engine operating conditions Maintenance instructions for EPA related engine parts Emission control system and adjustments Warranty statement Emission related installation instructions ENGIN...

Page 46: ...arest 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...

Page 47: ...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 q...

Page 48: ...lect or improper maintenance of your engine Your emission control system includes Air cleaner housing Cold air duct Turbocharger including wastegate ducting Unit Injectors Oil filler cap PCV positive...

Page 49: ...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...

Page 50: ...RANTY and covers 2008 and later EPA certified engines and applies to the following exhaust emission related components Air cleaner housing Cold air duct Turbocharger including wastegate ducting Unit I...

Page 51: ...ts 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 52: ...gine 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 e...

Page 53: ...components consistent with the EPA emission regulation requirements Electrical starter The electrical starter is fitted in connection with washers hex nuts and Allen screws Preparations Disconnect th...

Page 54: ...ncers The exhaust silencer is fitted in connection with washers hex nuts metal bellows and a protection plate Dismantling Remove in numerical sequence 1 7 Assembly Assemble in reverse sequence 53 2W35...

Page 55: ...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 ce...

Page 56: ...sion to the exhaust pipe 55 Version 2 Engine type d mm Version 1 HATZ Ident Nr Version 2 HATZ Ident Nr Clamp HATZ Ident Nr 2W35 38 830 857 000 830 858 00 037 409 00 3W35 38 830 857 000 830 858 00 037...

Page 57: ......

Page 58: ...TAL 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 INSTRUC...

Page 59: ...tions 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...

Page 60: ...mospheric 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...

Page 61: ...abrik 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 mee...

Page 62: ...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...

Page 63: ...andard 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 Air cleaner housi...

Page 64: ...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 A...

Page 65: ...gine 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 e...

Page 66: ...components consistent with the EPA emission regulation requirements Electrical starter The electrical starter is fitted in connection with washers hex nuts and Allen screws Preparations Disconnect th...

Page 67: ...ncers The exhaust silencer is fitted in connection with washers hex nuts metal bellows and a protection plate Dismantling Remove in numerical sequence 1 7 Assembly Assemble in reverse sequence 66 2W35...

Page 68: ...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 ce...

Page 69: ...sion to the exhaust pipe 68 Version 2 Engine type d mm Version 1 HATZ Ident Nr Version 2 HATZ Ident Nr Clamp HATZ Ident Nr 2W35 38 830 857 000 830 858 00 037 409 00 3W35 38 830 857 000 830 858 00 037...

Page 70: ...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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