Hatz Diesel 2G 40 H User manual

2G 40
2G 40 H
33
0000 433 302 06 -EN G -01.11 -0.2
Printed in Germany
Translation ofthe
ORIGINAL INSTRUCTION BOOK

A new HATZ Dieselengine -working foryou
This engine is intended only for the purpose determined and tested by the m anufacturer ofthe
equipm entin which itis installed.Using itin any other m anner contravenes the intended purpose.
For danger and dam age due to this,Motorenfabrik H ATZ assum es no liability. The risk is with the
useronly.
U se ofthis engine in the intended m anner presupposes com pliance with the maintenance and repair
instructions laid dow n for it.N oncom pliance leads to engine breakdow n.
Please do notfailto read thi
s operating manualbefore starting the engine.This willhelp you to avoid
accidents,ensure thatyou operate the engine correctly and assist you in com plying with the mainte-
nance intervals in orderto ensure long-lasting,reliable perfor
mance.
Please pass this Instruction M anualon to the next user orto the follow ing engine ow ner.
Alw ays have service work performedby qualified specialists.To this effect,werecom m end thatyou
consultone ofthe 500 HATZ service stations.There,your engine is repaired by staffw ho constantly
undergo training and who use both originalH ATZ spare part
s and H ATZ tools.The world-wide H ATZ
service network is also available to you for consultation and spare parts supply.
For the address ofyour nearest H ATZ service station,please refer to the attached list or the internet
under:www.hatz-diesel.com
The installation ofinappropriate spare parts maycause problem s.Wecannnotaccept any liability for
dam age or consequentialdam age resulting therefrom .
Thus,werecom m end thatyou use originalH ATZ spare parts. These parts are m anufactured follow -
ing the st
rict H ATZ specifications and ensure,thanks to theirperfect fitand function,maximum oper-
ating reliability. For the reference num ber,please consultthe attached spare partlist or the internet
under:www.hatz-diesel.com .
Please take the com plete spare parts kits in Table M 00 into account.
Wereserve the rightto m ake m odifications in the course oftechnicalprogress.
M OTORENFABRIK H ATZ GM BH & CO KG
1

2
Page
1. Im portantnotes on safe operation
ofthe engine 3
2. D escription ofthe engine 5
3. G eneralinformation 6
3.1. Technicaldata6
3.2. Transport7
3.3Instructions for installation 7
3.4. Load on engine 7
3.5. Type plate8
4. O peration 8
4.1. Before initialstart-up 8
4.1.1.Engine oil8
4.1.2.O ilbath aircleaner 9
4.1.3.Fuel 10
4.2. Starting the engine 11
4.2.1.Preparations for starting 11
4.2.2.Electric starter 11
4.3. Stopping the engine 13
5. M aintenance 14
5.1. M aintenace sum m ary14
5.2. M aintenance every 8 – 15
hours ofoperation 16
5.2.1.C heck engine oillevel 16
5.2.2.C heck com bustion airintake area 16
5.2.3.C heck the cooling airsystem 17
Page
5.3. M aintenance every 250
hours ofoperation 18
5.3.1.M aintenance work on oilbath
aircleaner 18
5.3.2.Engine oilchange and
oilfilter renew al 18
5.3.3.C heck and adjustvlave clearances 20
5.3.4.Clean the cooling airsystem 21
5.3.5.C heck threaded connections 22
5.4. M aintenance every 500
hours ofoperation 22
5.
4.1.R enew the fuelfilter 22
5.4.2.D ry-type aircleaner maintenance 23
6. Functionaltest 24
6.1. Airfilter maintenance indicators24
7. M alfunctions – Causes – Rem edies 25
8. W ork on the electrical system 29
9 .Protective treatm ent 29
Declaration for Incorporation 30
Contents
This sym bolidentifies im portant safety precautions.
Please com ply with these mostcarefully in order to avoid any risk ofinjury to persons or
dam age to materials.
Generallegalrequirem ents and safety regulations issued by the com petent authorit
ies or
industrialaccidentinsurers mustalso be com plied with.

1. Im portantnotes on safe operation ofthe engine
HATZ dieselengines are econom ical,stronly builtand long-lasting.They are therefore frequently
chosen forcom m ercially and industrially operated equipm entand machinery.
Since the engine formspartofthe finished equipm entor machine,its m anufacturer willtake allthe
applicable safety regulations into account.
N evertheless,wegive below certain additionalcomments on operating safety, and w ould recom m end
you to note them carefully.
Depend on the m anner in which the engine is installed and it
s intended application,the equipm ent
m anufacturer or operator mayhave to attach additionalsafety devices and prohibitpotentially
hazardous aspects ofoperation,forexam ple:
– Exhaustsystem com ponents as wellas the surface ofthe engine willnaturally be hotand mustnot
be touched while the engine is running or untilithas cooled dow n after being stopped.
– Faulty wiring or incorrect operation ofelectricalequipm entmaylead to sparks forming,and must
be avoided as a potentialfire hazard.
– Rotating parts mustbe shielded againstaccidentalcontact whenthe engine is installed in other
equipm entor machinery.
Guards are available from H ATZ to protect beltdrives to cooling fans and generators.
– Before attem pting to startt
he engine itis essentialto have studied the starting information in the
instruction book.
– M echanicalstarting devices mustnotbe used by children or persons ofinsufficient physical
strength.
– Before starting the engine,ensure that
allthe specified protective guards are in place.
– The engine mustonly be operated,serviced orrepaired by persons who have received the
appropriate trainig.
– Keep the ignition key outofreach ofunauthorized persons.
– Do notrun the engine in cl
osed or badly ventilated room s.
Do notbreath in em issions – dangerofpoisoning!
– Also fueland lubricants could contain poisonous com ponents.Please follow the instructions ofthe
mineraloilproducer (safety data sheets).
3

Im portantnotes on safe operation ofthe engine
– Stop the engine before performing any maintenance,cleaning- or repairwork.
– Stop the engine before refuelling.
N ever add fuelnear a naked flam e or a source ofsparks.
Don'tsm oke.D on'tspillfuel.
– Keep explosive materials as wellas fl
ammable materials aw ay from the engine because the exhaust
gets very hotduring operation.
– Wearclose-fitting clothing when working on a running engine.
Please don'twearnecklaces,bracelets or any other things which you could getcaughtwith.
– Please pay attention
to alladvice- and warning stickers placed on the engine and keep them in legi-
ble condition.In case a labelhas com e offoris no longer clearly legible,itmustbe replaced imme-
diately. To this effect,please contact the H ATZ service station in your area.
– Note thatany unauthorized m odification to the engine absolves its manufacturer from liability for
the consequences.
Regular servicing in accordance with the details provided in this instruction book is essentialto
keep
the engine operating reliably.
In case ofdoubt,alw ays consultyour nearestH ATZ service station before starting the engine.
4

2. D escription ofthe engine
5
Fig.1
1Fuelline (feed pum p –
fuel-injection pum p)
2Airdeflector
3Oildipstick
4Fuelreturn line
5Injector
6Lifting eyebolt
7Starter motor
8Airguide
9Airintake pipe
10 Type plate
11 G low plug
(additionalequipm ent)
12 O ilbath aircleaner
13 O il
pressure sw itch
14 R ainproofcap
15 O ilfiller cap
16 Fuelpressure pipe
17 Cylinder head cover
18 Engine oilline
19 Exhaustmanifold
20 Fuelinjection pum p
21 Stop lever
22 S peed controllever
23 Fuelfeed pum p
24 Engine oilfilter
25 O ildrain plug
26 G uard
27 Airguide housing
28 Separ
able connector
29 Voltage regulator
30 Engine m ount
31 Crankshaft,pow er-take-off
32 Fuelline
(fuelfilter -feed pum p
33 Fuelfilter

3. G eneralrem arks
3.1. Technicaldata
Type 2 G 40 /2G 40H
Design Air-cooled four-stroke dieselengine
Com bustion system D irectinjection
Num berofcylinders2
Bore/stroke m m 92 /75
Displacem ent cm ³ 997
Engine oilcontent 2.5 excl.sum p
1)
incl.filter renew al l.approx. 3.0 incl.sum p
1)
Difference betw een
„m ax“ and „m in“ levelsl.approx. 0.8
1)
Engine oilpressuremin. 1 bar at 900 r.p.m.engine speed
Engine oilconsum ption
(after running-in period) approx. 1% offuelconsum ption at fullload
Direction ofrotation,
pow er take-offend anti-clockw ise
Valve clearances at 10 -30 °C
Inlet/exhaust m m 0.10
Max.permissible perm.inclination Exhaust Flyw heel
Angle ofinclination in °low high low high
withoutoilsum p 30
2)
17
2)
25
2)
25
2)
with oilsum p 30
2)
17
2)
30
2)
25
2)
Weight(incl.fueltank,air-cleaner,kg
exhaustsilencer and electric starter)approx. 106
Battery capacitymin /m ax 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 breakdow n.
6

3.2. Transport
2
The lifting eyeboltprovided as stand-
ard equipm entis intended forsafe
m ovem entofthe engine.
Itis notintended for lifting com plete machin-
ery to which the engine is attached,and this is
strictly forbidden.
3.3. Instructions for installation
Ifyou have an engine which is notyet installed
in a machine and stillhas to be installed,make
sure thatthe Assem bly Instructions forHATZ
DieselEngines are com plied with prior to instal-
lation.These Assem bly Instructions contain
im-
portant information aboutsafe assem bly ofthe
engine and are available from your the H ATZ
service center in your area.
Pending com plete installation,the engine
mustnotbe started !
Moreover,wew ould like to pointoutthatin this
case,com m issioning ofthe machine is also pro-
hibited untilithas been verified thatthe machine
into which this engine is to be incorporated
com plies with allthe safety precautions and reg-
ulations provided by law .
Refer also to
the Declaration for Incorporation
at the end ofthese Operating Instructions.
3
The permitted loads and elem ents on
the speed adjusting leverand the stop
lever should be observed as an exess can lead
to dam age to the contacts and inner governor
parts.
3.4. Load on engine
Operating the engine for a lengthy period off-
load orat very low loads can affect its running
quality.
Wetherefore recom m end a minimum engine
load of15 %.Ifoperated atsuch low loads,itis
bestto operate the engine at a
significantly high-
er load fora shortperiod before sw itching itoff.
7

8
3.5. Type plate
4
The type plate is placed on the airguide (Fig.1,
pos.10)and includes the follow ing engine infor-
mation:
➀engine type
➁code (only forspecialequipm ent)
➂engine num ber
➃max.engine speed
For any offer as wellas spare parts orders itis
necessary to mention these data (also see spare
parts list,page 1).
➀➁
➂
➃
4. O peration
4.1. Before initialstart-up
Engines are normally delivered withoutfueland
oil.
4.1.1. Engine oil
Oilquality
Qualified are alltradem ark oils which fulfilat
least one ofthe follow ing specifications:
ACEA – B2 /E2 or more significant
API– CD /CE /CF /CF-4 /CG-4ormore
significant.
Ifengine oil
ofa poorer quality is used,reduce
oilchange intervals to 150 hours ofoperation.
Oilviscosity
5
Please select the recom m ended viscosity de-
pending on the am bient tem perature at which
the engine is operated.
Inappropriate engine oilmayshorten the
engine’s service life significantly.
-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
10 W / 4 0
10 W / 3 0
15 W /40
30
40
122
10 W

Whenadding oilor checking the level,the en-
gine mustbe in a horizo n talposition.
6
– Rem ove oilfiller screw „1 “ and dipstick „2 “.
– Add engine oilup to the max.mark on the
dipstick.
Lubricating oilcapacity:see Chapter 3.1.
– Insertthe oilfiller screw and tighten it(hand-
tightonly).
Attention !
Ifthe engine is operated while the oillevelis
below the min. m ark or above the max.mark,
itcan cause dam age to the engine.
4.1.2. O ilbath aircleaner
7
Ifa cyclone-type dusttrap is fitted,makesure
thatthe dustoutlet is pointing in the correct
direction.
– Fillthe oiltank up to mark „1 “ with engine oil.
– Attach oiltank „2 “, making sure thatsealing
ring „3 “ is correctly seated and clips „4 “ are
fastened securely.
9

4.1.3. Fuel
8
Stop the engine before refuelling.
Neveradd fuelnear a naked flam e or
a source ofsparks. D on'tsm oke. Use only pure
fueland clean filling equipm ent.Take care not
to spillfuel.
Dieselfuelcom plying with the minimum require-
ments of
the follow ing specifications maybe
used:
EN 590 or
BS 2869 A1 /A2 or
ASTM D 975 -1D/2D
Im portant!
The use offuels ofdifferentspecifications
requires the prior written consentofthe HATZ
headquarters.
9
Before starting for the first timeor ifthe fuel
system wasrun dry, primeitby operating lever
„1“ on feed pum p „2 “ untilfuelis heard to flow
back into the fueltank through the return line.
Attem perat
ures below 0 °C , winter-grade fuel
should be used or paraffin added to the fuelwell
in advance.
Low estam bient
tem perature when
starting,in °C
Paraffin content for:
Sum m er W inter
fuel fuel
0upto –10 20 %–
–10 up to –15 30 %–
–15 up to –20 50 % 20 %
–20 up to –30 – 50 %
10

4.2. Starting the engine
Do notrun the engine in closed or
badly ventilated room s – danger of
poisoning!
Before starting the engine,makesure thatno
one is within the danger area near the engine
orthe machinery itis driving, and thatallthe
necessary guards are
installed.
4.2.1. Preparations for starting
– Ifpossible,disengage the engine from any
driven equipm ent
The auxiliary equipm entshould alwaysbe
placed in neutral.
10
– D epending on operation conditions and re-
quirem ents,setspeed controllever „1 “ to ei-
ther the 1/2 START or max.START position.
– Makesure thatstop lever „2 “ is in the off
position „S TA R T “.
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11
Neveruse starting aids in the form of
aerosols or sprays!
4.2.2. Electric starter
– For starting preparations,see Chapter 4.2.1.
12
– Insertthe startkey to its stop and turn itto
position I.
Battery charge telltale „2 “ and oilpressure
warning light„3 “ willcom e on.
– Turn startkey to position II
11

– As soon as the engine runs,release the start
key. Itmustreturn to position Iby itselfand
rem ain in this position during operation.
The battery charge telltale and oilpressure
warning mustgo outimmediately after star
t-
ing.Indicator light„1 “ is on when the engine
is in operation.
– The engine tem perature display „4 “ (additional
equipm ent)lights up ifthe tem perature at the
cylinder head becom es too high.
Sw itch offthe engine and trace and elimi
-
nate the cause ofthe problem ,chapter 7.
– The aircleaner maintenance indicator „5 “
(additionalequipm ent)only lights up during
operation ifthe aircleaner elem ent needs to
be cleaned or renew ed (chapter 5.4.2.).
– Alwaysturn the st
artkey 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 dam aged
while the engine is stillrunning.
Im portant!
Ifa starter protect
ion m odule is fitted,the key
mustbe turned back to position 0for at least
8 seconds ifthe engine fails to start,before a
second attem pt ofstarting can be made.
Note:
Startformax.30 seconds.Ifthe engine does
notrun
after this time,turn starter key back to
position 0 and eliminate the cause,Chapter 7.
Preheating device with autom atic heating
timer(additionalequipm ent)
The preheating light„6 “ lights up additionally at
tem peratures below 0° Celsius (Fig.12).
–After the lighthas gone out,startthe engine
withoutdelay.
Autom atic shut-
dow n function
(additionalequipm ent)
This is characterized by a brief flashing ofall
pilotlam ps once the starter key has been turned
to position I(Fig.12).
Im portant!
Ifthe engine cuts outimmediately after starting
orsw i
tches offby itselfduring operation,a mon-
itoring elem ent in the autom atic shutdow n sys-
tem has tripped.The corresponding indicator
light(Fig.12,positions 2 -4) willcom e on.After
the engine has stopped,the display conti
nues to
glow for about2 minutes.
The electricaldevice then sw itches itselfoffau-
tom atically.
The display lights up again after the startkey
has been turned back to position 0andthen to
position Iagain.
Trace and eliminate the cause
ofthe
operating faultbefore trying to restartthe
engine (see chapter 7).
The display lightgoes outwhenthe engine is
nextstarted.
Even with autom atic shutdow n m onitoring the
oillevelmustbe checked every 8–15 operat-
ing hours (chapter
5.2.1.).
12

4.3. Stopping the engine
13
– Movespeed controllever „1 “ back to the
„S T O P “ position.
– On engines with the low er idling speed outof
use, movespeed controllever „1“ back,then
movestop lever „2 “ tow ards STOP and hold it
there untilthe engine has com e to a standstill.
– O nce the engine is notrunning any longer,
release the stop lever.The stop lever is re-
turned autom atically to its operating position
START via a spring.
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14
– The battery charge telltale light„2 “ and the oil
pressure warning light„3 “ com e on.
– Turn the starter key back to position „0“ and
pullitout.The telltale and warning lights must
go out.
Note:
Engines with an autom atic electricalshutdow n
system can also be stopped by turning the
starter key back to positon „0“.
During breaks in operation oratthe
end ofthe work session,pulloutthe
starter key and keep in a safe place w here it
cannotbe reached by unauthorized persons.
3
2
13

14
5. M aintenance
5.1. M aintenance summary
Maintenance interval M aintenance work required Chap.
The engine mustbe stopped before any maintenace work is attem pted.
Com ply with legalrequirem ents w hen handling and disposing ofold oil,filters and
cleaning materials.
Keep the engine's starting key and starting handle outofreach ofunauthorize d persons.
To im m obilize engines with an electric starter,disconnectthe negative battery terminal.
Atthe end ofthe maintnance work, check thatalltools have been rem oved from the engine and
allsafety guards, covers etc. replaced in theircorr
ectpositions.
Before starting the engine,makesure thatno-one is in the dangerarea (engine or driven
machinery).
Every 8 – 15
operating hours or
before daily starting
C heck oillevel.
C heck area around com bustion airinput.
C heck cooling airsystem .
C heck thatthe oillevelin the low erpartofthe
oilbath aircleaner is correct and thatthe oilis
notcontam inated.
5.2.1.
5.2.2.
5.2.3.
4.1.2.
5.3.1.
Every 250
operating hours
Maintenance ofairfilter/oilbath airfilter.
Replace engine oiland oilfilter.
Check and adjustvalve clearances.
Clean cooling airsystem .
Exam ine screw connections.
5.3.1.
5.3.2.
5.3.3.
5.3.4.
5.3.5.
Every 500
operation hours
Renew fuelfilter.
Maintenance ofairfilter/dry-airfilter
5.4.1.
5.4.2.
250
500
8- 15

The above maintenance chartis supplied with
every engine.This labelshould be affixed to the
engine or equipm entin an easily visible position.
The maintenance chartgoverns the maintenance
intervals.
For new or reconditioned engines,the follow ing
mustalwaysbe carried outafter the first25
operating hours.
– Replace engine oiland oilfilter,chap.5.3.2.
– C heck tappetclearance,and adjustifnecess-
ary,chap.5.3.3.
– Exam ine screw connections,chap.5.3.5.
Forshortoperating periods:replace engine oil
and oilfilter after 12 m onths atthe latest,
regardless ofthe num ber ofoperating hours.
15

5.2. M aintenance work every 8 – 15
operating hours
5.2.1.C heck engine oillevel
Whenthe oillevelis checked,the engine must
be stopped and in a horizontalposition.
– R em ove any dirtin the dipstick area.
15
– For oillevelinspection,rem ove the dipstick „2 “
and wipe itdry using a lint-free,clean piece of
cloth;then insertitto its stop and pullitout
again.
– Check oillevelat the dipstick;top up if
necessary as far as the „max“mark (see
Chapter 4.1.1.).
Attention !
Ifthe engine is operated while the oillevelis
below the min. m ark or above the max.mark,it
can cause dam age to the engine.
5.2.2. C heck com bustion airintake area
H eavy contam ination is an indication thatin-
creased dustaccum ulation necessitates a corre-
spondingly shorter maintenance interval,
Chapter 5.3.1.and 5.4.2.
With oilbath aircleaner:
16
– Inspectairinlets „1 “ (depending on version)
for severe dirtand dustdeposits,and clean if
necessary.
– M ake sure thatdustoutlet „2 “ on the
cyclone-type dusttrap (depending on version)
is notobstructed, and clean ifnecessary
(chap.5.3.1.).
With
dry-type aircleaner:
17
– Inspectairinlets „1 “ and clean ifnecessary.
– C heck thatdustdischarge valve „2“ is notob-
structed;eliminate dustblockage by pressing
together as show n.
16

17
– Check thatconnecting hose „3 “ and hose clips
„4“ are in good condition and notleaking
(fig.17).
18
– Run the engine up to maximum speed briefly
and check thatindicatorlam p „1 “ (depending
on version) com es on briefly or thatthe red
zone is visible in maintenance indicator „3 “.
5.2.3. Check the cooling airsystem
H eavy contam ination is an indication thatin-
creased dustaccum ulation necessitates acorre-
spondingly shorter maintenance interval.
19
– Inspectairinlets and outlets for coarse soiling
such as leaves,dustaccum ulation etc.,clean if
necessary (chap. 5.3.4.).
The tem perature indicator„1 “ – ifinstalled – will
lightup as soon as the engine becom es
too hot.
Shutdow n the
engine immediately!

5.3. M aintenance work every 250
operating hours
5.3.1. M aintenance work on oilbath
aircleaner
20
Trap the old oiland dispose ofitin
accordance with locallegislation.
– Take offthe oiltank „1 “.
– R em ove contam inated oiland sludge from the
oiltank,and clean itout.
– Take offrain cap „2“ orcyclone-type dusttrap
„3 “, and clean.
– Clean rightthrough intake pipe „4 “
– Check condition ofsealing ring „5 “ and renew
ifnecessary.
– Add engine oilto the oiltank up to mark „6“
and re-assem ble the oilbath aircleaner
(fig.20,chap.4.1.2.).
Ifthe fi
lter packing is severely contam inated with
dustand dirt,the upper partofthe aircleaner
mustalso be cleaned as follow s:
21
– Detach upper partofaircleaner „1 “ from
engine and rinse in dieselfuel.
– Allow the dieselfueldrip offthoroughly, or
wipe itoff,before re-assem bling.
– Installa new filter packing ifthe sealing sur-
face is uneven,the body ofthe filter is cracked
and/orfilter w oolis missing.
– Installthe upper partofthe aircleaner,using a
new flange gasket „3 “.
– Re-assem ble the rem aining parts ofthe air
cleaner and fill
with oilto prepare forfurther
operation (chap.4.1.2.).
5.3.2. Engine oilchange and
oilfilter renew al
The engine mustbe stopped and in a horizontal
position.
Drain the engine oilonly when the engine is
warm.
D anger ofscalding from hotoil!
Trap the old oiland dispose ofitin
accordance with locallegislation.
18

22
23
– Take outdrain plug „1 “ and allow the oilto
drain outcom pletely (fig.22 withoutoilsum p,
fig.23 with oilsum p).
– Insertoildrain plug „1 “ with a new sealing
ring „2 “ and tighten.
24
– Slacken offand unscrew the throw aw ay engine
oilfilter using H ATZ strap wrench „1 “, Order
No.620 307 01,or a similar tool.
25
– Usea screw driver to liftmeshscreen „1 “,
which is located behind the filter elem ent,
aw ay from the oilpressure reliefvalve.
Do notdam age contact face „2 “.
– Clean meshscreen „1“ from the inside by
blow ing through with com pressed air.
Persons handl
ing com pressed airmust
w earprotective goggles.Neverdirect
the jetto animals, persons or yourself!
G3/28
19