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Hatz 3L43C, Manual

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Hatz 3L43C Manual Download Page 86

Maintenance

3-4L43C, 3-4M43, 3-4M43Z

86

HATZ

Manual

Procedure

Step

Activity

1

Disconnect the signal line (1) from the exhaust gas back pres-
sure sensor (2) by loosening the connector fastener.

2

Unscrew the line connection (3) and remove the exhaust gas
back pressure sensor.

3

Check the bore hole for the exhaust gas back pressure sensor.
When the bore hole is blocked with soot, the exhaust gas back
pressure sensor must be replaced.

4

Refit the exhaust gas back pressure sensor and reconnect the
signal line.

8.2.19 Resetting the maintenance interval indicator

After completion of maintenance work reset the maintenance interval indica-
tor. The counter starts again at zero and indicates when the next service is
due.

Overview — HATZ instrument boxes

I

0

1

Starting key

2

Pushbutton

Ignition lock

0

Off

I

Operation

Summary of Contents for 3L43C

Page 1: ...CREATING POWER SOLUTIONS MANUAL for diesel engine Hatz Diesel 3 4L43C 3 4M43 3 4M43Z www HATZ DIESEL com...

Page 2: ......

Page 3: ...4 Technical data 21 4 1 Engine information and filling quantities 21 4 2 Engine type plate 23 4 3 Engine oil 24 4 4 Fuel 25 5 Engine design 26 6 Transport assembly and commissioning 30 6 1 Transport 3...

Page 4: ...nce 69 8 2 13 Changing the oil filter 72 8 2 14 Change the main fuel filter 73 8 2 15 Renewing the poly v belt and checking the function of the switch off unit 76 8 2 16 Replacing the diesel particula...

Page 5: ...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 th...

Page 6: ...bal 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 u...

Page 7: ...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 t...

Page 8: ...est 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...

Page 9: ...tate 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 b...

Page 10: ...njury 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...

Page 11: ...ve 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 manu...

Page 12: ...ety 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...

Page 13: ...strict 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...

Page 14: ...ired 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 fr...

Page 15: ...fety 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 ensu...

Page 16: ...t gas sys tem Do not operate and place the engine in the direct vicinity of combustible materials 3 2 3 Machine specific safety instructions for maintenance work Introduction The machine can pose resi...

Page 17: ...foreign bodies Safety instructions for maintenance work DANGER Danger of explosion from flammable cleaning agents Cleaning with benzene is an explosion hazard It is highly flammable can become electro...

Page 18: ...tive 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 d...

Page 19: ...al wiring diagrams can be requested when needed We cannot be held liable for electrical equipment that is not designed according to HATZ wiring diagrams Promptly replace faulty indicator lamps Do not...

Page 20: ...Utilizarsolamente aceitelow SAPSoil 0000 043 129 00 Only use engine oil with the relevant specification see chapter 4 3 En gine oil page 24 0000 036 144 CAUTION Damage from inadequate engine cooling...

Page 21: ...e oil consumption 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 0 10 Net weigh...

Page 22: ...ode letter on the dipstick 3L43C With 10 5 D Without 8 0 A 3M43 With 11 0 D Without 8 5 A 3M43Z With 10 5 D Without 8 0 A 4L43C With 13 0 D 4M43 With 14 0 D 4M43Z With 13 0 D 2 These values are approx...

Page 23: ...umping start crankshaft before top dead center 3 Engine serial number 4 Max engine speed rpm 5 Model year 6 Displacement liters and inspection requirement for special settings 7 Injection pump effecti...

Page 24: ...the functionality and service life of the catalytic converter and or particulate filter Only use engine oils with very low quantities of sulfate ash phosphor and sulfur so called low SAPS oils which f...

Page 25: ...A2 USA ASTM D 975 09a 1 D S15 or 2 D S15 Japan JIS K 2204 with a maximum HFRR value of 520 m CAUTION Danger of engine damage from low quality fuel The use of fuel that does not meet the specification...

Page 26: ...26 HATZ Manual 5 Engine design Engine 3 4L43C sealed version Silent Pack 1 2 3 4 5 6 7 8 9 10 11 16 17 18 12 13 14 15 19 20 21 22 23 24 25 Pos Designation 1 Air intake duct for capsule 2 Intake openin...

Page 27: ...ine type plate 10 Oil filter 11 Cover plate on operating side 12 Fuel return line 13 Manual fuel pump 14 Fuel feed line with fuel prefilter 15 Battery connections 16 Engine mount 17 Oil drain screw 18...

Page 28: ...4M43 3 4M43Z 28 HATZ Manual Engine 3 4M43 3 4M43Z standard version 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22 24 25 26 23 Pos Designation 1 Fuel filter 2 Powerbox 3 Central connector fo...

Page 29: ...l filter 11 Engine mount 12 Manual fuel pump 13 Fuel feed line with fuel prefilter 14 Battery connections 15 Oil drain screw on oil sump 16 Drain screw on the water separator 17 Fuel return line 18 Li...

Page 30: ...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 machi...

Page 31: ...correct 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 equip...

Page 32: ...ge 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 an...

Page 33: ...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 th...

Page 34: ...ith an empty fuel system Pump the fuel with the manual fuel pump see chapter 7 3 1 Pumping fuel with the manual fuel pump page 34 7 3 1 Pumping fuel with the manual fuel pump Requirements Pre pumping...

Page 35: ...sible 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 g...

Page 36: ...the area of the exhaust emission after treatment system 12 Regeneration of the diesel particulate filter not possible 13 Regeneration of the diesel particulate filter is activated 14 Regeneration of...

Page 37: ...tact Hatz service if the oil level is correct Air filter maintenance indicator not activated NOTE A dirty air filter unit can be identified by the corresponding flash ing signal in the indicator for F...

Page 38: ...culate filter page 45 Pushbutton The pushbutton fulfills the following functions Suppress regeneration of the diesel particulate filter When this button is pressed maximum 2 seconds a regen eration th...

Page 39: ...shooting see chapter 9 1 Trouble shooting page 88 NOTICE i If the engine stops again immediately after starting or stops independently during operation this is an indication that a monitoring element...

Page 40: ...esignation 1 Starting key Ignition lock 0 Off I Operation Procedure Step Activity 1 Turn the starting key 1 to position 0 The engine switches off All indicator lamps go out 2 Remove the starting key N...

Page 41: ...ies 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...

Page 42: ...ct any escaped water fuel mixture and dispose of it ac cording to local environmental regulations NOTICE i The interval for checking the water separator depends entirely on the proportion of water in...

Page 43: ...se of the water fuel mixture in accordance 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 th...

Page 44: ...1 Dipstick 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 mu...

Page 45: ...otes DANGER Danger of fire from hot exhaust gas system The exhaust gas system and in particular the diesel particulate filter can become very hot Combustible materials can ignite on the exhaust gas sy...

Page 46: ...eneration of the diesel particulate filter not possi ble 4 Indicator Regeneration of the diesel particulate filter is acti vated 5 Indicator Regeneration of the diesel particulate filter was sup press...

Page 47: ...is too low The regeneration process can not be started Remedy Increase the engine load NOTE The way the engine load is increased depends on the re spective use of the engine If possible do not reduce...

Page 48: ...on 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...

Page 49: ...t 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 f...

Page 50: ...ce 3 4L43C 3 4M43 3 4M43Z 50 HATZ Manual 3 4M43 3 4M43Z 0000 042 956 01 max 3 4L43C 0 1 mm 0 004 L43 1h 250h 500h L o w S A P S A C E A E 6 A C E A E 9 A P I C J 4 max Low SAPS ACEA E6 ACEA E9 API CJ4...

Page 51: ...per ating hours or ev ery day before starting Check the oil level 7 8 Checking the oil level and adding oil if necessary page 43 Check the intake area of the combustion air 8 2 3 Checking the in take...

Page 52: ...aporizer and clean if necessary page 81 Check the exhaust gas back pressure sensor 8 2 18 Checking the ex haust gas back pres sure sensor page 85 Reset the maintenance inter val indicator 8 2 19 Reset...

Page 53: ...s a danger of burns when working on a hot engine Let the engine cool Wear safety gloves NOTICE i In case of heavy contamination shorten the maintenance inter vals accordingly see chapter 8 2 2 Mainten...

Page 54: ...urns There is a danger of burns when working on a hot engine Let the engine cool before maintenance CAUTION Danger of injury When working with compressed air foreign bodies may fly into your eyes Wear...

Page 55: ...oil cooler page 58 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...

Page 56: ...with an open end wrench 2 Screw in the cleaned oil drain screw 1 with the new gasket and tighten Overview Checking oil level adding oil Pos Designation 1 Dipstick 2 Code letter on the dipstick Proced...

Page 57: ...UTION 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 cove...

Page 58: ...ination 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 15 Renewing the poly v belt and checking the fun...

Page 59: ...lay option lights up as soon as the engine becomes impermissibly hot Switch off the engine immediately and eliminate the cause CAUTION Danger of damage to the machine from incorrect engine cleaning Le...

Page 60: ...tivity 1 On encapsulated engines unscrew the following see chapter 5 Engine design page 26 Hood Side panel Cover plate on operating side Air outlet duct for cooling air Cover plate on air outlet side...

Page 61: ...sulated 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 ter...

Page 62: ...crews for attaching the cylinder head The adjustment screws on the speed governor and the in jection system are secured with locking varnish and are not permitted to be tightened or adjusted Only reti...

Page 63: ...on 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 f...

Page 64: ...al environmental regulations 5 Insert a new fuel prefilter Note the following Direction of arrow for the flow through direction depends on position of the fuel tank HIGH or LOW Installation position f...

Page 65: ...ecked depending on the degree of contamina tion Renew the filter cartridge after a use period of 500 operating hours Four cylinder engines have two filter cartridges Overview Removing the air filter c...

Page 66: ...ditionally 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...

Page 67: ...pacer 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 11 Checking and cleaning the...

Page 68: ...ces 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 thro...

Page 69: ...old 10 30 C Let the engine cool CAUTION Damage from inadequate engine cooling Only operate the engine when all covers are installed Overview Preparatory activities Pos Designation 1 Square opening 2 H...

Page 70: ...ening 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...

Page 71: ...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 nut 1 is tightened again 3 Repeat the above procedure for the...

Page 72: ...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 Overview 1 Oil filter 2 Strap wrench 3 Ga...

Page 73: ...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...

Page 74: ...Dirt particles can damage the injection system Maintain clean conditions to ensure dirt does not enter the fuel line Only install fuel filters dry and do not prefill in order to avoid contamination O...

Page 75: ...ockwise 2 Dispose of the old filter in accordance with local environmental regulations 3 Lightly oil the gasket 2 of the new fuel filter 4 Mount the fuel filter and tighten it by hand 5 Open the fuel...

Page 76: ...machine will not switch off automatically if the belt tears If the grooves are broken off or bent renew the damaged pulley Overview Removing the poly v belt Pos Designation 1 Cylinder screw 2 Tension...

Page 77: ...belt moni toring system Step Activity 1 Release the piston with the tension pulley 1 by removing the cylinder screw The piston with the tension pulley is pushed out of the housing by spring pressure T...

Page 78: ...Mounting the poly v belt Step Activity 1 Slide in the switch off pin 1 2 Slide the piston with the tension pulley 2 into the housing 3 and lock it using the cylinder screw 3 Position the poly v belt...

Page 79: ...l screws 8 2 16 Replacing the diesel particulate filter Safety notes CAUTION Danger of burns During the regeneration process the diesel particulate filter and the exhaust system become very hot There...

Page 80: ...rting the engine page 35 The conditioning of the diesel particulate filter must be car ried out by a specialized company In order to ensure shut down periods as short as possible the Hatz EasyClean ex...

Page 81: ...he diesel particulate filter discharge funnel and dif ferential pressure line in reverse order NOTE The installation direction of the diesel particulate filter is deter mined by the design Only tighte...

Page 82: ...or toward yourself CAUTION Damage to the coiled filament from wire brush Clean the coiled filament only with a soft copper or brass wire brush Do not use a hard steel wire brush Overview Removing the...

Page 83: ...rator unit mounting bolts 2 4 Carefully slacken the evaporator unit the gasket 3 should not be damaged The gasket can be reused if it remains undam aged 5 Remove the complete evaporator unit from the...

Page 84: ...evaporator housing see section Cleaning the fuel evaporator vaporizer Procedure Cleaning the fuel evaporator Step Activity 1 Brush off soot deposits from the coiled filament 2 with a cop per or brass...

Page 85: ...gloves CAUTION Damage to the exhaust gas back pressure sensor by clean ing The exhaust gas back pressure sensor is destroyed by cleaning in the majority of cases The correct operation of the sensor ca...

Page 86: ...ust gas back pressure sensor When the bore hole is blocked with soot the exhaust gas back pressure sensor must be replaced 4 Refit the exhaust gas back pressure sensor and reconnect the signal line 8...

Page 87: ...the button 2 2 Turn the starting key from position 0 to position I 3 Release the button 2 after a wait time of at least 5 seconds but no longer than 10 seconds The maintenance interval indicator is n...

Page 88: ...fuel with the manual fuel pump page 34 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 9 Changing the fuel pre...

Page 89: ...ed Change the engine oil and oil filter Add engine oil with a suitable viscosity class 8 2 5 Change the engine oil page 55 Insufficiently charged battery Check the battery and contact the service cent...

Page 90: ...gnal from monitoring elements that are associated with the au tomatic switch off optional No oil pressure Check the oil level 7 8 Checking the oil level and adding oil if nec essary page 43 Faulty thr...

Page 91: ...cessary 3 2 4 Electrical equipment page 18 Faulty three phase alternator Faulty relay The engine loses power and speed Possible causes Remedy Chapter Dirty air filter unit Check the degree of dirt con...

Page 92: ...8 Checking the oil level and adding oil if nec essary page 43 Inadequate cooling Contamination in the entire area of the cooling air guides Clean the cooling air area 8 2 7 Cleaning the cooling fan c...

Page 93: ...ling system Clean the cooling air area 8 2 7 Clean ing the cool ing fan cooling fins and oil cooler page 58 Incompletely closed air guide parts or capsule parts Check the air guide parts and shafts fo...

Page 94: ...rsist please contact your nearest HATZ service Flashing signal Flashing Pause Possible causes Remedy Chapter 1 1 Area affected Exhaust gas recir culation EGR Faulty cabling to the EGR sensor Check the...

Page 95: ...as back pressure sensor Differential pres sure sensor Temperature sensors on the diesel oxidation catalytic con verter DOC Contact Hatz ser vice 7 1 Area affected Electronic speed control Faulty speed...

Page 96: ...o different control units Check the cabling contact Contact Hatz ser vice 14 1 Area affected Air filter mainte nance display Dirty air filter unit Service the air fil ter 8 2 10 Main taining the dry a...

Page 97: ...een interrupted several times by engine stops If permitted by the working environ ment do not switch off the engine dur ing the regenera tion process Operation of the fuel evaporator impaired Check th...

Page 98: ...shes on the instrument box see Explanation of symbols chapter 7 4 Starting the engine page 35 The table below shows possible flashing signals and their meaning The cor responding maintenance activitie...

Page 99: ...xhaust 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...

Page 100: ...ain fuel filter page 73 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 t...

Page 101: ...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 cou...

Page 102: ...the interfaces 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...

Page 103: ......

Page 104: ...ONS 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 436 003 03 10 2016 0 1 P...

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