Hatz Diesel 2G 40 H User manual

INSTRUCTION BOOK
2G40
2G40 H
33
433 316 05-USA-EPA IV-CARB
12.07-0.05
Printed in Germany
INCLUDES 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 CALIFORNIA
REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES

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 2008 and later
EPA certified nonroad compression-ignition engines or for 2008 and later California certified
Heavy-Duty off-road engines to prevent our environment.
Please pass this Instruction Manual on to the next user or to the following engine owner.
The worldwide HATZ Service Network is at your disposal to advise you, supply with spare parts and
undertake servicing work.
You will find the address of your nearest HATZ service station in the enclosed list.
Use only original spare parts from HATZ. Only these parts guarantee a perfect dimensional stability
and quality. The order numbers can be found in the enclosed spare parts list. Please note the spare
part kits shown in Table 1.
We reserve the right to make modifications in the course of technical progress.
MOTORENFABRIK HATZ GMBH & CO KG
1

Contents
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 plates 8
3.6. Emission-related installation instructions 9
4. Operation 9
4.1. Before initial start-up 9
4.2. Starting the engine 11
4.3. Stopping the engine 13
5. Maintenance 14
5.1. Maintenance summary 14
5.2. Maintenance every 8 – 15 hours of operation 16
5.3. Maintenance every 250 hours of operation 17
5.4. Maintenance every 500 hours of operation 21
6. Functional test 23
6.1. Air filter maintenance indicators 23
7. Malfunctions – Causes – Remedies 24
8. Work on the electrical system 27
9. Protective treatment 27
SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 AND LATER
EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES 29
SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 MODEL YEAR
AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES 43
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 are also applicable.
2

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.
3

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. Contact your next HATZ Servicestation, if a sticker comes off or is illegible and ask
for a new one.
– 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.
4

2. Description of the engine
5
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 / 2 G 40 H
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 Amp/h max. 12V / 88Ah – 24V / 88Ah
1) These values are intended as an approximate guide. The max. marking „3“ on the dipstick is the
determining factor, Fig. 6.
2) Exceeding these limits causes engine breakdown.
6

3.2. Transport
2
The lifting eyebolt provided as stand-
ard equipment is intended for safe
movement of the engine with its auxiliaries.
Its maximum load capacity is 150 kg. It is not
intended for lifting complete machinery to
which the engine is attached, and this is strict-
ly forbidden.
3.3. Instructions for installation
The „Manual for Selection and Installation of En-
gines“ 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 this manual from your
nearest HATZ service station.
3
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 29; resp. supplemental informa-
tion for California regulations for off road
engines, Page 43.
7

8
3.5. EPA/CARB-type plates and
fuel label
There are two EPA/CARB- type plates applied for
the identification of the engine. The type plates
are placed on the air guide (chapt. 2).
They include the following emission control in-
formation (Figure 4a):
Label 1/2
4a
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
➇“constant speed only” (if requested)
➈“variable speed” (if requested)
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.
➀
➁
➂
➃➄
➅
➆
➇➈
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
The layout is identical for constant-speed and
variable speed application.
Attention:
If the engine was certified for constant-speed
application and shall be used so, the field “con-
stant-speed only” is marked with “X”.
If the engine was certified for variable speed ap-
plication and shall be used so, the field “variable
speed” is marked with “X”.
Always install the engine for its intended applica-
tion in order to comply with EPA and CARB
emission regulation requirements.
Label 2/2
4b
The engine must be operated with “LOW SUL-
FUR FUEL OR ULTRA LOW SULFUR FUEL
ONLY”.
The label also states the applicable emission-
related power category of the engine.
EMISSION CONTROL INFORMATION
LOW SULFUR FUEL OR
ULTRA LOW SULFUR FUEL ONLY
Power category:
❏< 8 kW / ❏ 8-19kW / ❏ 19-37kW /
❏37-56 kW PM Standard: 0.3 g/kWh
Label 2/2

Fuel label
4c
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 29; resp. supplemental informa-
tion for California regulations for off road
engines, Page 43.
LOW SULFUR FUEL OR ULTRA
LOW SULFUR FUEL ONLY
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
5
Choose an engine oil with a viscosity category
that matches the ambient temperature when
starting from cold.
-40
-30
-20
-10
0
10
20
30
40
50
10 4
86
68
50
32
14
-4
-22
-40
OIL: SAE...
°C°F
5W/30
5W/40
10W/40
10W/30
15W/40
30
40
122
10 W
9

When adding oil or checking the level, the en-
gine must be in a horizontal position.
6
– Remove oil filler screw „1“ and dipstick „2“.
– Add engine oil until the level reaches upper
mark „3“ on the dipstick (fig. 6, chap. 3.1.).
– Insert the oil filler screw and tighten it (hand-
tight only).
– After a short test run, check engine oil level
again and correct if necessary.
4.1.2. Oilbath air cleaner
7
If a cyclone-type dust trap is fitted, make sure
that the dust outlet is pointing in the correct
direction (fig. 7).
– Fill the oil tank up to mark „1“ with engine oil.
– Attach oil tank „2“, making sure that sealing
ring „3“ is correctly seated and clips „4“ are
fastened securely.
4.1.3. Fuel
8
Stop the engine before refuelling.
Never add fuel near a naked flame or
a source of sparks. Don't smoke. Use only pure
fuel and clean filling equipment. Take care not
to spill fuel.
Diesel fuel complying with the minimum require-
ments of the following specifications may be
used:
EN 590 or
DIN 51601 - DK or
BS 2869 A1 / A2 or
ASTM D 975 - 1D/2D
10

9
Before starting for the first time or if the fuel
system was run dry, prime it by operating lever
„1“ on feed pump „2“ until fuel is heard to flow
back into the fuel tank through the return line.
At temperatures below 0 °C, winter-grade fuel
should be used or paraffin added to the fuel well
in advance.
Lowest ambient
temperature when
starting, in °C
Paraffin content for:
Summer Winter
fuel fuel
0 up to –10 20 % –
–10 up to –15 30 % –
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %
4.2. Starting the engine
Do not run the engine in closed or
badly ventilated rooms – danger of
poisoning!
Before starting the engine, make sure that no
one is within the danger area near the engine
or the machinery it is driving, and that all the
necessary guards are installed.
4.2.1. Preparations for starting
– If possible, disengage the engine from any
driven equipment
The auxiliary equipment should always be
placed in neutral.
10
– Depending on operation conditions and re-
quirements, set speed control lever „1“ to ei-
ther the 1/2 START or max. START position.
– Make sure that stop lever „2“ is in the off
position „START“.
Start
Run
Stop
Start
Stop
11

11
Never use starting aids in the form of
aerosols or sprays !
4.2.2. Electric starter
– For starting preparations, see Chapter 4.2.1.
12
– Insert the key to its stop and turn it to
position I.
– Battery charge telltale „2“ and oil pressure
warning „3“ must light up.
– Turn start key to position II.
– As soon as the engine runs, release the start
key. It must return to position I by itself and
remain in this position during operation.
The battery charge telltale and oil pressure
warning must go out immediately after start-
ing. Indicator light „1“ is on when the engine
is in operation.
– The engine temperature display „4“ (additional
equipment) lights up if the temperature at the
cylinder head becomes too high.
Switch off the engine and trace and elimi-
nate the cause of the problem, see chapter 7.
– The air cleaner maintenance indicator „5“
(additional equipment) only lights up during
operation if the air cleaner element needs to
be cleaned or renewed (see Chapter 5.4.2.).
– Always turn the start key back to position 0
before re-starting the engine. The repeat lock
in the ignition lock prevents the starter motor
from engaging and possibly being damaged
while the engine is still running.
Important !
If a starter protection module is fitted, the key
must be turned back to position 0 for at least
8 seconds if the engine fails to start, before a
second attempt of starting can be made.
Preheating device with automatic heating
timer (additional equipment)
The preheating light „6“ lights up additionally at
temperatures below 0° Celsius (Fig. 12).
– After the light has gone out, start the engine
without delay.
12

4.3. Stopping the engine
13
– Move speed control lever „1“ back to the
„STOP“ position.
– On engines with the lower idling speed out of
use, move speed control lever „1“ back, then
move stop lever „2“ towards STOP and hold it
there until the engine has come to a standstill.
– After the engine has ceased to run, release
stop lever „2“, making sure that it returns to
its original „START“ position.
Start
Run
Stop
Start
Stop
14
The charge 2and oil pressure pilot lamps 3
come on.
– Turn the ignition key to the 0 position and pull
it out. The pilot lamp lights must then go out.
Note:
Engines with an automatic electrical shutdown
system can also be stopped by turning the igni-
tion key back to positon „0“.
During breaks in operation or at the
end of the work session, pull out the
ignition key and keep in a safe place where it
cannot be reached by unauthorized persons.
3
2
13

14
5. Maintenance
5.1. Maintenance summary
Maintenance interval Maintenance work required Chap.
The engine must be stopped before any maintenace work is attempted.
Comply with legal requirements when handling and disposing of old oil, filters and
cleaning materials.
Keep the engine's key and starting handle out of reach of unauthorized persons.
To immobilize engines with an electric starter, disconnect the negative battery terminal.
At the end of the maintnance work, check that all tools have been removed from the engine and
all safety guards, covers etc. replaced in their correct positions.
Before starting the engine, make sure that no-one is in the danger area (engine or driven
machinery).
Every 8 – 15
operating hours or
before daily starting
Check oil level.
Check area around combustion air input.
Check cooling air system.
Check that the oil level in the lower part of the
oil bath air cleaner is correct and that the oil is
not contaminated.
5.2.1.
5.2.2.
5.2.3.
4.1.2.
5.3.1.
Every 250
operating hours
Maintenance of air filter/oil bath air filter.
Replace engine oil and oil filter.
Check and adjust valve clearances.
Clean cooling air system.
Examine screw connections.
5.3.1.
5.3.2.
5.3.3.
5.3.4.
5.3.5.
Every 500
operation hours
Renew fuel filter.
Maintenance of air filter/dry-air filter
5.4.1.
5.4.2.
250
500
8- 15

The above maintenance chart is supplied with
every engine. This label should be affixed to the
engine or equipment in an easily visible position.
The maintenance chart governs the maintenance
intervals.
For new or reconditioned engines, the following
must always be carried out after the first 25
operating hours.
– Replace engine oil and oil filter, chap. 5.3.2.
– Check tappet clearance, and adjust if necess-
ary, chap. 5.3.3.
– Examine screw connections, chap. 5.3.5.
For short operating periods: replace engine oil
and oil filter after 12 months at the latest,
regardless of the number of operating hours.
15

5.2. Maintenance work every 8 – 15
operating hours
5.2.1. Check engine oil level
When the oil level is checked, the engine must
be stopped and in a horizontal position.
15
– Check the oil level at dipstick „2“, add oil if ne-
cessary until the level reaches upper mark „3“
(chap. 4.1.1.).
5.2.2. Check combustion air intake area
Heavy contamination is an indication that in-
creased dust accumulation necessitates a corre-
spondingly shorter maintenance interval,
Chapter 5.3.1. and 5.4.2.
With oilbath air cleaner:
16
– Inspect air inlets „1“ (depending on version)
for severe dirt and dust deposits, and clean if
necessary.
– Make sure that dust outlet „2“ on the
cyclone-type dust trap (depending on version)
is not obstructed, and clean if necessary
(chap. 5.3.1.).
With dry-type air cleaner:
17
– Inspect air inlets „1“ and clean if necessary.
– Check that dust discharge valve „2“ is not ob-
structed; eliminate dust blockage by pressing
together as shown.
16

17
– Check that connecting hose „3“ and hose clips
„4“ are in good condition and not leaking
(fig. 17).
18
– Run the engine up to maximum speed briefly
and check that indicator lamp „1“ (depending
on version) comes on briefly or that the red
zone is visible in maintenance indicator „3“.
5.2.3. Check the cooling air system
Heavy contamination is an indication that in-
creased dust accumulation necessitates acorre-
spondingly shorter maintenance interval.
19
1
– Inspect air inlets and outlets for coarse soiling
such as leaves, dust accumulation etc., clean
if necessary (fig. 19, chap. 5.3.4.).
The temperature indicator „1“ – if installed – will
light up as soon as the engine becomes
too hot.
Shut down the engine immediately !
5.3. Maintenance work every 250
operating hours
5.3.1. Maintenance work on oilbath
air cleaner
20
– Take off oil tank „1“ and clean it.
– Take off rain cap „2“ or cyclone-type dust trap
„3“, and clean.
– Clean right through intake pipe „4“
– Check condition of sealing ring „5“ and renew
if necessary.
– Add engine oil to the oil tank up to mark „6“
and re-assemble the oilbath air cleaner
(fig. 20, chap. 4.1.2.).
If the filter packing is severely contaminated
with dust and dirt, the upper part of the air
cleaner must also be cleaned as follows:

21
– Detach upper part of air cleaner „1“ from
engine and rinse in diesel fuel.
– Allow the diesel fuel drip off thoroughly, or
wipe it off, before re-assembling.
– Install a new filter packing if the sealing sur-
face is uneven, the body of the filter is cracked
and/or filter wool is missing.
– Install the upper part of the air cleaner, using a
new flange gasket „3“.
– Re-assemble the remaining parts of the air
cleaner and fill with oil to prepare for further
operation (chap. 4.1.2.).
5.3.2. Engine oil change and
oil filter renewal
The engine must be stopped and in a horizontal
position.
Drain the engine oil only when the engine is
warm.
Danger of scalding from hot oil !
Trap the old oil and dispose of it in
accordance with local legislation.
22
23
– Take out drain plug „1“ and allow the oil to
drain out completely (fig. 22 without oil sump,
fig. 23 with oil sump).
– Insert oil drain plug „1“ with a new sealing
ring „2“ and tighten.
18

24
– Slacken off and unscrew the throwaway engine
oil filter using HATZ strap wrench „1“, Order
No. 620 307 01, or a similar tool.
25
– Use a screwdriver to lift mesh screen „1“,
which is located behind the filter element,
away from the oil pressure relief valve.
Do not damage contact face „2“.
– Clean mesh screen „1“ from the inside by
blowing through with compressed air.
– After cleaning, press the mesh screen back on
to the oil pressure relief valve.
Never re-use the throwaway filter element.
1
G3/28
2
26
– Clean sealing face „1“ thoroughly.
– Oil sealing ring „2“ on the new filter element
lightly.
– Screw in throwaway filter element „3“
handtight.
– Add engine oil (chap. 4.1.1.).
– Run the engine briefly to check that there
are no leaks at the oil filter; take up slack if
necessary.
Check the oil level; add oil if necessary.
19