Hatz 2-4L41C User manual

INSTRUCTION BOOK
433 402 07 - ENG - 06.08 - 2
Printed in Germany 33
2-4L41C
2-4M41.
4L42C
4M42

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 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
1

Page
1. Important notes on safe operation
of the engine 3
2. Description of engine 5
3. General information 9
3.1. Technical data 9
3.2. Transport 10
3.3 Installation instructions 10
3.4. Load on engine 10
3.5. Type plate 10
4. Operation 11
4.1. Before initial start-up 11
4.1.1. Engine oil 11
4.1.2. Fuel 12
4.2. Starting the engine 13
4.2.1. Starting with the electric starter 14
4.2.2. Emergency starting 16
4.2.3. Starting with handle 16
4.2.4. Starting with the handle with
kick-back damping 18
4.3. Stopping the engine 19
5. Maintenance 20
5.1. Maintenance summary 20
5.2. Maintenance every 8 – 15
hours of operation 23
5.2.1. Check engine oil level 23
5.2.2. Check combustion air intake area 23
5.2.3. Check the cooling air system 25
Page
5.3. Maintenance every 250
hours of operation 25
5.3.1. Engine oil change 25
5.3.2. Cleaning cooling fan, cooling fins
and oil cooler 26
5.3.3. Checking threaded connections 28
5.3.4. Cleaning of mesh insert in
exhaust pipe 28
5.3.5. Check water trap 29
5.4. Maintenance every 500
hours of operation 29
5.4.1. Replace fuel pre-filter 29
5.4.2. Air cleaner maintenance 30
5.4.3. Checking and adjusting
valve clearances 33
5.4.4. Engine oil change 34
5.4.5. Renewing oil filter 34
5.5. Maintenance every 1000
hours of operation 35
5.5.1. Renewing the fuel filter 35
6. Operating checks and repair work 37
6.1. Checking operation of air cleaner
maintenance indicator 37
6.2. Renewing fan drive belt, checking
operation of belt monitor 38
7. Malfunctions – causes and remedies 41
8. Work on the electrical system 45
9. Protective treatment 45
2
Contents
This symbol draws attention to important safety precautions.
Please comply with them most carefully in order to avoid any risk of injury to persons or
damage to materials.
General legal requirements or safety regulations issued by the competent authorities or
industrial accident insurers are also applicable.

1. Important notes on safe operation of the engine
HATZ diesel engines are economical, strongly built and long-lasting. They are therefore frequently
chosen for commercially and industrially operated equipment and machinery.
If the engine forms part of the finished equipment or machine, its manufacturer will take all the appli-
cable safety regulations into account.
Nevertheless, we would like you to note certain additional comments on operating safety which
follow. Depending 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 poten-
tially 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 so that they cannot be touched accidentally when the engine is in-
stalled in other equipment or machinery.
Guards are available from HATZ to protect belt drives for 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.
– In order to benefit from the advantages of the starting handle with kick-back damping, it must be
used precisely as recommended in this Instruction Book.
– 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 appro-
priate training.
– Keep the starting handle and the 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- and repair work.
– Stop the engine before refuelling.
Never refuel near a naked flame or sparks which could start a fire. 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 the engine while it is running.
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 service station, if a sticker comes off or is illegible and ask
for a new one.
– Note that any unauthorized modifications to the engine absolve its manufacturer from liability for
the consequences.
Regular servicing in accordance with the details provided in this Instruction Book is essential to keep
the engine operating reliably.
In case of doubt, always consult your nearest HATZ service station before starting the engine.
4

2. Description of engine
Fully encapsulated „Silent Pack“ version
Engine 2 ...4L41C
5
1 Access cover for fuel delivery pump
2 Oil filler pipe and dipstick
3 Type plate
4 Speed control lever
5 Replaceable-element oil filter
6 Exhaust silencer (in capsule)
7 Cover for air guide housing
(Access to fan drive belt)
8 Engine support feet
9 Oil drain plug
10 Cover plate, control side
11 Side panel
12 Air outlet duct
13 Capsule hood
14 Suspension lug (retractable),
max. load 5000 N
15 Air intake duct for capsule
16 Combustion air intake aperture
17 Fuel feed line line with fuel pre-filter
18 Fuel return line
19 Cover plate, air outlet side
20 Central plug for electrical system
21 Battery connections
22 Power-Box
23 Electrical maintenance switch for
air cleaner
1

Description of engine
Fully encapsulated „Silent Pack“ version
Engine 4 L 42 C
6
1 Electronic control unit
2 Oil filler pipe and dipstick
3 Type plate
4 Speed control lever
5 Replaceable-element oil filter
6 Exhaust silencer (in capsule)
7 Cover for air guide housing
(Access to fan drive belt)
8 Engine support feet
9 Oil drain plug
10 Cover plate, control side
11 Side panel
12 Air outlet duct
13 Capsule hood
14 Suspension lug (retractable),
max. load 5000 N
15 Air intake duct for capsule
16 Combustion air intake aperture
17 Fuel feed line with fuel pre-filter and
manual fuel pump
18 Fuel return line
19 Cover plate, air outlet side
20 Central plug for electrical system
21 Battery connections
22 Power-Box
23 Electrical maintenance switch for
air cleaner
24 Fuel filter
2

Description of engine
Standard version
Engine 2 ... 4 M 41 • 2 ... 4 M 41 Z
7
1 Oil filler pipe and dipstick
2 Side panel
3 Combustion air intake aperture
4 Cooling fan drive belt
5 Cooling fan with alternator attached
6 1/2-inch intl. hex socket for turning over
engine
7 Oil drain plug
8 Speed control lever
9 Replaceable-element oil filter
10 Oil drain plug (if sump is fitted)
11 Cooling air duct for engine oil cooler
12 Access cover for fuel delivery pump
13 Cylinder head cover
14 Air cleaner cover
15 Suspension lug, max. load 5000 N
16 Fuel return line
17 Fuel feed line with fuel pre-filter
18 Type plate
19 Exhaust silencer
20 Central plug for electrical system
21 Battery connections
22 Power-Box
23 Electrical maintenance switch for
air cleaner
3

Description of engine
Standard version
Engine 4 M 42
8
4
1 Oil filler pipe and dipstick
2 Side panel
3 Combustion air intake aperture
4 Cooling fan drive belt
5 Cooling fan with alternator attached
6 1/2-inch intl. hex socket for turning over
engine
7 Oil drain plug
8 Speed control lever
9 Replaceable-element oil filter
10 Oil drain plug (if sump is fitted)
11 Cooling air duct for engine oil cooler
12 Fuel filter
13 Cylinder head cover
14 Air cleaner cover
15 Suspension lug, max. load 5000 N
16 Fuel return line
17 Fuel feed line with fuel pre-filter and
manual fuel pump
18 Type plate
19 Exhaust silencer
20 Central plug for electrical system
21 Battery connections
22 Power-Box
23 Electrical maintenance switch for
air cleaner
24 Exhaust gas return valve (EGR)
25 Electronic control unit

9
3. General information
3.1. Technical data
2L41C 3L41C 4L41C / 4L42C
2 M 41. 3 M 41. 4 M 41. / 4 M 42.
Type Air-cooled, four-stroke diesel engine
Combustion method Direct fuel injection
Number of cylinders 2 3 4
Bore/stroke mm 102 / 105 102 / 105 102 / 105
Displacement cm³ 1716 2574 3432
Engine oil pressure
Oil temperature 100 ± 20°C min. 0.6 bar at 850 r.p.m.
Consumption of lubrication max. 1 % of fuel consumption
oil after running-in period at full-load
Direction of rotation Counterclockwise, looking at flywheel
Valve clearance (at 10 - 30 °C)
Inlet/exhaust mm 0.10
Net weight
.M41 258 308 373
.M41 Zapprox. 263 315 388
4M42 kg 378
.L41 C303 363 433
4L42 C438
Max. angle from vertical in any with and without with without only with
direction (in continuous operation) sump sump sump
Control side 30° 1) 30° 1) 25° 1) 25° 1)
Air outlet side 30° 1) 30° 1) 30° 1) 30° 1)
Timing gear side 30° 1) 25° 1) 25° 1) 15° 1)
Flywheel side 30° 1) 22° 1) 25° 1) 18° 1)
1) Exceeding these limits causes engine breakdown.