Hatz Diesel 2G40 H Kurzanleitung

2G40 | 2G40 H

www.HATZ-DIESEL.com

Hatz Diesel

CREATING POWER SOLUTIONS.

Translation of the

ORIGINAL

INSTRUCTION BOOK

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A new HATZ Diesel engine - working for you

This engine is intended only for the purpose determined and tested by the manufacturer of the

equipment in which it is installed. Using it in any other manner contravenes the intended purpose.

For danger and damage due to this, Motorenfabrik HATZ assumes no liability. The risk is with the

user only. Use of this engine in the intended manner presupposes compliance with the maintenance

and repair instructions laid down for it. Noncompliance leads to engine breakdown.

Please do not fail to read this operating manual before starting the engine. This will help you to avoid

accidents, ensure that you operate the engine correctly and assist you in complying with the mainte-

nance intervals in order to ensure long-lasting, reliable performance.

Please follow all maintenance references carefully including the schedule for Model Year 2015

EPA certified nonroad compression-ignition engines to prevent our environment.

Please pass this Instruction Manual on to the next user or to the following engine owner.

Always have service work performed by qualified specialists. To this effect, we recommend that you

consult one of the 500 HATZ service stations. There, your engine is repaired by staff who constantly

undergo training and who use both original HATZ spare parts and HATZ tools. The world-wide HATZ

service network is also available to you for consultation and spare parts supply.

For the address of your nearest HATZ service station, please refer to the attached list or the internet

under: www.hatz-diesel.com

The installation of inappropriate spare parts may cause problems. We cannnot accept any liability for

damage or consequential damage resulting therefrom.

Thus, we recommend that you use original HATZ spare parts. These parts are manufactured follow-

ing the strict HATZ specifications and ensure, thanks to their perfect fit and function, maximum oper-

ating reliability. For the reference number, please consult the attached spare part list or the internet

under: www.hatz-diesel.com. Please take the complete spare parts kits in Table M00 into account.

We reserve the right to make modifications in the course of technical progress.

MOTORENFABRIK HATZ GMBH & CO KG

Page

1. Important notes on safe operation

of the engine 3

2. Description of the engine 5

3. General information 6

3.1. Technical data 6

3.2. Transport 7

3.3 Instructions for installation 7

3.4. Load on engine 7

3.5. EPA / CARB - type plate 8

3.6. Emission-related installation

instructions 8

4. Operation 9

4.1. Before initial start-up 9

4.1.1. Engine oil 9

4.1.2. Oilbath air cleaner 10

4.1.3. Fuel 10

4.2. Starting the engine 11

4.2.1. Preparations for starting 11

4.2.2. Electric starter 12

4.3. Engine use 13

4.4. Stopping the engine 14

5. Maintenance 15

5.1. Maintenace summary 15

5.2. Maintenance every 8 – 15

hours of operation 17

5.2.1. Check engine oil level 17

5.2.2. Check combustion air intake area 17

5.2.3. Check the cooling air system 18

Page

5.3. Maintenance every 250

hours of operation 19

5.3.1. Maintenance work on oilbath

air cleaner 19

5.3.2. Engine oil change an

oil filter renewal 19

5.3.3. Check and adjust vlave clearances 21

5.3.4. Clean the cooling air system 22

5.3.5. Check threaded connections 23

5.4. Maintenance every 500

hours of operation 23

5.4.1. Renew the fuel filter 23

5.4.2. Dry-type air cleaner maintenance 24

6. Functional test 25

6.1. Air filter maintenance indicators 25

7. Malfunctions – Causes – Remedies 26

8. Work on the electrical system 30

9. Protective treatment 30

Declaration for Incorporation 31

SUPPLEMENTAL INFORMATION TO

THE OWNER’S MANUAL FOR Model

Year 2015 EPA CERTIFIED NONROAD

COMPRESSION IGNITION ENGINES 33

SUPPLEMENTAL INFORMATION TO

THE OWNER'S MANUAL FOR THE USE

OF EPA CERTIFIED ENGINES WITHIN

CALIFORNIA 47

Contents

This symbol identifies important safety precautions.

Please comply with these most carefully in order to avoid any risk of injury to persons or

damage to materials.

General legal requirements and safety regulations issued by the competent authorities or

industrial accident insurers must also be complied with.

1. Important notes on safe operation of the engine

HATZ diesel engines are economical, stronly built and long-lasting. They are therefore frequently

chosen for commercially and industrially operated equipment and machinery.

Since the engine forms part of the finished equipment or machine, its manufacturer will take all the

applicable safety regulations into account.

Nevertheless, we give below certain additional comments on operating safety, and would recommend

you to note them carefully.

Depend on the manner in which the engine is installed and its intended application, the equipment

manufacturer or operator may have to attach additional safety devices and prohibit potentially

hazardous aspects of operation, for example:

– Exhaust system components as well as the surface of the engine will naturally be hot and must not

be touched while the engine is running or until it has cooled down after being stopped.

– Faulty wiring or incorrect operation of electrical equipment may lead to sparks forming, and must

be avoided as a potential fire hazard.

– Rotating parts must be shielded against accidental contact when the engine is installed in other

equipment or machinery.

Guards are available from HATZ to protect belt drives to cooling fans and generators.

– Before attempting to start the engine it is essential to have studied the starting information in the

instruction book.

– Mechanical starting devices must not be used by children or persons of insufficient physical

strength.

– Before starting the engine, ensure that all the specified protective guards are in place.

– The engine must only be operated, serviced or repaired by persons who have received the

appropriate trainig.

– Keep the ignition key out of reach of unauthorized persons.

– Do not run the engine in closed or badly ventilated rooms.

Do not breath in emissions – danger of poisoning!

– Also fuel and lubricants could contain poisonous components. Please follow the instructions of the

mineral oil producer (safety data sheets).

Important notes on safe operation of the engine

– Stop the engine before performing any maintenance, cleaning- or repair work.

– Stop the engine before refuelling.

Never add fuel near a naked flame or a source of sparks.

Don't smoke. Don't spill fuel.

– Keep explosive materials as well as flammable materials away from the engine because the exhaust

gets very hot during operation.

– Wear close-fitting clothing when working on a running engine.

Please don't wear necklaces, bracelets or any other things which you could get caught with.

– Please pay attention to all advice- and warning stickers placed on the engine and keep them in legi-

ble condition. In case a label has come off or is no longer clearly legible, it must be replaced imme-

diately. To this effect, please contact the HATZ service station in your area.

– Note that any unauthorized modification to the engine absolves its manufacturer from liability for

the consequences.

Regular servicing in accordance with the details provided in this Instruction Book is essential to keep

the operating reliably and to ensure the exhaust quality of the engine.

In case of doubt, always consult your nearest HATZ service station before starting the engine.

2. Description of the engine

Fig. 1

1 Fuel line (feed pump –

fuel-injection pump)

2 Air deflector

3 Oil dipstick

4 Fuel return line

5 Injector

6 Lifting eyebolt

7 Starter motor

8 Air guide

9 Air intake pipe

10 Type plate

11 Glow plug

(additional equipment)

12 Oilbath air cleaner

13 Oil pressure switch

14 Rainproof cap

15 Oil filler cap

16 Fuel pressure pipe

17 Cylinder head cover

18 Engine oil line

19 Exhaust manifold

20 Fuel injection pump

21 Stop lever

22 Speed control lever

23 Fuel feed pump

24 Engine oil filter

25 Oil drain plug

26 Guard

27 Air guide housing

28 Separable connector

29 Voltage regulator

30 Engine mount

31 Crankshaft, power-take-off

32 Fuel line

(fuel filter - feed pump

33 Fuel filter

3. General remarks

3.1. Technical data

Type 2G40 / 2G40H

Design Air-cooled four-stroke diesel engine

Combustion system Direct injection

Number of cylinders 2

Bore/stroke mm 92 / 75

Displacement cm³ 997

Engine oil content 2.5 excl. sump 1)

incl. filter renewal l. approx. 3.0 incl. sump 1)

Difference between

„max“ and „min“ levels l. approx. 0.8 1)

Engine oil pressure min. 1 bar at 900 r.p.m. engine speed

Engine oil consumption

(after running-in period) approx. 1% of fuel consumption at full load

Direction of rotation,

power take-off end anti-clockwise

Valve clearances at 10 - 30 °C

Inlet/exhaust mm 0.10

Max. permissible perm. inclination Exhaust Flywheel

Angle of inclination in ° low high low high

without oil sump 30 2) 17 2) 25 2) 25 2)

with oil sump 30 2) 17 2) 30 2) 25 2)

Weight (incl. fuel tank, air-cleaner, kg

exhaust silencer and electric starter) approx. 106

Battery capacity min / max 12 V - 45 / 88 Ah •24 V - 36 / 55 Ah

1) These values are intended as an approximate guide. The max. marking on the dipstick is the

determining factor, Fig. 6.

2) Exceeding these limits causes engine breakdown.

3.2. Transport

The lifting eyebolt provided as stand-

ard equipment is intended for safe

movement of the engine.

It is not intended for lifting complete machin-

ery to which the engine is attached, and this is

strictly forbidden.

3.3. Instructions for installation

If you have an engine which is not yet installed

in a machine and still has to be installed, make

sure that the Assembly Instructions for HATZ

Diesel Engines are complied with prior to instal-

lation. These Assembly Instructions contain im-

portant information about safe assembly of the

engine and restricted engine use of EPA/CARB

certified engines.

These instructions are available from the HATZ

service center in your area.

Pending complete installation, the engine

must not be started !

Moreover, we would like to point out that in this

case, commissioning of the machine is also pro-

hibited until it has been verified that the machine

into which this engine is to be incorporated

complies with all the safety precautions and reg-

ulations provided by law.

Refer also to the Declaration for Incorporation

at the end of these Operating Instructions.

The permitted loads and elements on

the speed adjusting lever and the stop

lever should be observed as an exess can lead

to damage to the contacts and inner governor

parts.

3.4. Load on engine

See supplemental information for EPA certified

engines, Page 33.

3.5. EPA/CARB-type plate and

fuel label

The layout of the EPA / CARB - type plate depends

on the engine application and is placed on the

air guide (chapt. 2).

It includes the following emission control infor-

mation (Figure 4a):

Type plate

➀EPA / CARB - Engine Family Number

➁engine type / spec. (only for special

equipment) /Fuel Delivery Timing

➂engine number

➃max. engine rated speed

➄build date

➅displacement

➆rated power

➇emission control system information (see

page 36 and 50)

➈“variable speed” or “constant speed only”

(if requested)

The type plate also states the applicable emis-

sion-related power category of the engine.

The figure of the lable shows a EPA/CARB (50

states) label. The text referring to the emission

regulation gets printed depending on the engine

equipment (EPA or EPA and CARB).

VARIABLE SPEED. ULTRA LOW SULFUR FUEL ONLY.

Power Category:

EMISSION CONTROL SYSTEM INFORM.:

➀

➁

➂

➃➄

➅

➆

➈

➇

Every engine is equipped with an additional

loose engine type plate. If the original type

plate on the engine is not readily visible after

the engine is installed in the equipment then

the second loose type plate must be attached

on the equipment in such a manner that it is

readily visible to an 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):

➁engine type / spec.

(only for special equipment)

➂engine number

➃max. engine rated speed

Always install the engine for its intended applica-

tion in order to comply with EPA and CARB

emission regulation requirements.

Fuel label

The engine must be operated with “ULTRA LOW

SULFUR FUEL ONLY”.

The fuel label is placed nearby the fuel inlet.

If there was no fuel tank mounted to the engine,

the label has to be permanently attached to the

equipment near the fuel inlet.

3.6. EMISSION-RELATED

INSTALLATION INSTRUCTIONS

See supplemental information for EPA certified

engines, Page 33.

0000 053 657 02

4. Operation

4.1. Before initial start-up

Engines are normally delivered without fuel and

oil.

4.1.1. Engine oil

Oil quality

Qualified are all trademark oils which fulfil at

least one of the following specifications:

ACEA – B2 / E2 or more significant

API – CD / CE / CF / CF-4 / CG-4 or more

significant.

If engine oil of a poorer quality is used, reduce

oil change intervals to 150 hours of operation.

Oil viscosity

Please select the recommended viscosity de-

pending on the ambient temperature at which

the engine is operated.

Inappropriate engine oil may shorten the

engine’s service life significantly.

-40

-30

-20

-10

10 4

-4

-22

-40

OIL: SAE...

°C°F

5W/30

5W/40

10W/40

10W/30

15W/40

122

10 W

When adding oil or checking the level, the en-

gine must be in a horizontal position.

– Remove oil filler screw „1“ and dipstick „2“.

– Add engine oil up to the max. mark on the

dipstick.

Lubricating oil capacity: see Chapter 3.1.

– Insert the oil filler screw and tighten it (hand-

tight only).

Attention !

If the engine is operated while the oil level is

below the min. mark or above the max. mark,

it can cause damage to the engine.

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