Hatz 2W35 User manual

433 916 01-USA-EPA IV-CARB
12.07-0.03
Printed in Germany
INSTRUCTION BOOK
33
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
2W35
3W35
4W35
4W35T

A new HATZ Diesel engine - working for you
This engine is intended only for the purpose determined and has been 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 for the first time.
This will help you to avoid accidents, ensure that you operate the engine correctly and assist you
in complying with the maintenance 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 and for 2008 and later CARB certified
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
parts kits shown in Table M00.
We reserve the right to make modifications in the course of technical progress.
MOTORENFABRIK HATZ GMBH & CO KG
1

Page
1. Important safety notes
when operating the engine 4
2. Description of the engine 6
3. General notes 10
3.1. Technical data 10
3.2. Transport 11
3.3. Instructions for installation 11
3.4. Load on engine 11
3.5. EPA / CARB - type plates 12
3.6. Emission-related installation
instructions 13
4. Operation 13
4.1. Before initial start-up 13
4.1.1. Engine oil 13
4.1.2. Coolant 14
4.1.3. Fuel 16
4.2. Starting the engine 18
4.2.1. Preparations for starting 18
4.2.2. Electric starter 19
4.3. Stopping the engine 20
5. Maintenance 22
5.1. Maintenance chart 22
5.2. Maintenance every 8 - 15
operating hours 24
5.2.1. Check engine oil level 24
5.2.2. Check combustion air intake area 24
5.2.3. Check air cleaner maintenance
indicator 25
5.2.4. Check radiator fins for contamination 25
5.2.5. Check coolant level 25
Page
5.3. Maintenance every 250
operating hours 26
5.3.1. Change engine oil 26
5.3.2. Check water trap 26
5.3.3. Clean the radiator fins 27
5.3.4. Check screw connections 28
5.3.5. Check the Vee belt 28
5.4. Maintenance every 500
operating hours 29
5.4.1. Replace primary fuel filter 29
5.4.2. Replace the engine oil filter 30
5.4.3. Air cleaner maintenance 31
5.5. Maintenance every 1000
operating hours 34
5.5.1. Renew the fuel filter 34
5.6. Maintenance: every 4 years 35
5.6.1. Replacement of coolant 35
6. Malfunctions – causes – remedies 37
7. Work on the electrical system 41
8. Storage out of use 41
SUPPLEMENTAL INFORMATION TO
THE OWNER’S MANUAL FOR 2008
AND LATER EPA CERTIFIED NONROAD
COMPRESSION IGNITION ENGINES 43
SUPPLEMENTAL INFORMATION TO
THE OWNER’S MANUAL FOR 2008
AND LATER CALIFORNIA
REGULATIONS FOR HEAVY-DUTY
OFF-ROAD ENGINES 57
3
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 safety notes when operating the engine
HATZ diesel engines are efficient, strong and durable. For this reason they are mostly installed on
equipment used for commercial purposes.
The manufacturers of such equipment must observe any relevant equipment safety regulations when
the engine forms part of an overall system.
A few general points concerning operating safety should nonetheless be noted.
Depending on the engine's operating and installation conditions, equipment manufacturers and their
users may have to fit safety or protective devices in order to prevent improper use. Examples:
– 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.
– Incorrect wiring or improper operation of the electrical system may cause sparking and must there-
fore be avoided.
– Provide protection against contact with rotating parts once the engine is connected to the driven
equipment or machine.
HATZ protective guards are available for the belt drive of the cooling fan and alternator drive
systems.
– Always observe the start-up information in the operating instructions before starting the engine.
– Mechanical starting devices should not be operated by children or persons deficient in physical
strength.
– Check that all safety devices are in place before starting the engine.
– Ensure that operation, maintenance and repair of the engine are undertaken by suitably trained
personnel only.
– Protect the starter key against unauthorised use.
– Do not run the engine in closed or insufficiently ventilated rooms.
Do not breathe in emissions – danger of poisoning!
– Also fuel and lubricants could contain poisonous components. Please follow the appropriate
instructions of the mineral oil producer.
– Radiator protection fluids are detrimental to health. Thus, they may only be stored in closed original
containers and in a place inaccessible to non-authorized persons. Eye and skin contact must be
avoided. Comply with the manufacturer’s instructions
4

Important safety notes when operating the engine
– The engine must be stopped before performing any maintenance, cleaning or repair work.
– It is essential to stop the engine before refilling the fuel tank.
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.
– Never spill consumables, such as fuel, oil or radiator protection fluid over hot engine components.
The fluid might catch fire.
– Work on the cooling system must not be performed while the engine is warm - risk of scalding !
The cooling system is pressurized.
– Wear close-fitting clothing only when working on the engine while it is running.
Please don’t wear necklaces, bracelets or any other objects which you could get caught with.
– Please pay attention to all advice- and warning stickers placed on the engine and keep them in
legible condition. Contact your next HATZ service station if a sticker comes off or is illegible and
ask for a new one.
– We accept no liability for damage resulting from improper modifications to the engine.
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.
When in doubt, consult your local HATZ service station before starting the engine.
5

2. Description of the engine 2 W 35 • 3 W 35 • 4 W 35
6
MOTORENFABRIKHATZKG
D-94099RUHSTORF
MADEINGERMANY
11
17
16
15
13
12
1
2
3
4
5
6
7
8
10 9
14
1Operator’s side
1 Speed adjustment lever
2 Type plate
3 Coolant pump
4 Oil dipstick
5 Oil filler cap
6 Drain plug for coolant
7 Oil drain plug (governor side)
8 Engine mountings (optional equipment)
9 Oil drain plug (operator’s side)
10 Engine oil filter
11 Water drain plug on fuel filter
12 Oil pressure switch
13 Fuel filter with water trap
14 Dry-type air cleaner
15 Combustion air intake port
16 Fuel suction line connector
17 Fuel pre-filter

Description of the engine 2 W 35 • 3 W 35 • 4 W 35
7
1 Fuel feed pump
2 Fuel return line
3 Stop lever (optional equipment)
4 Exhaust silencer
5 Exhaust gas outlet
6 Electrical starter
7 Central plug for electrical system
8 Oil drain plug (exhaust side)
9 Voltage regulator
10 Fan (optional equipment)
11 Radiator (optional equipment)
12 Coolant supply to engine
13 Coolant return to radiator and thermostat
14 Temperature switch
15 Coolant expansion tank (optional
equipment)
16 Vent line to expansion tank
17 Cylinder head cover
1
2
3
4
5
6
7
8
11
14
13
12
9
15 16
10
17
2Exhaust side

Description of the engine 4 W 35 T (turbocharged engine)
8
MOTORENFABRIKHA
TZKG
D-94099RUHSTORF
MADEINGERMANY
1
2
3
4
5
6
7
8
10
15
14
13
9
11
17
19
12
16
18
3Operator’s side
1 Speed adjustment lever
2 Type plate
3 Coolant pump
4 Oil dipstick
5 Fan (optional equipment)
6 Hydraulic pump drive (optional equipment)
7 Flange for additional hydraulic pump
(optional equipment)
8 Oil drain plug (governor side)
9 Engine mountings (optional equipment)
10 Oil drain plug (operator’s side)
11 Oil filler cap
12 Engine oil filter
13 Water drain plug on fuel filter
14 Oil pressure switch
15 Fuel filter with water trap
16 Dry-type air cleaner
17 Combustion air intake port
18 Fuel suction line connector
19 Fuel pre-filter

9
Description of the engine 4 W 35 T (turbocharged engine)
1 Fuel feed pump
2 Fuel return line
3 Stop lever or stop solenoid
(optional equipment)
4 Turbocharger
5 Exhaust flange
6 Electric starter
7 Oil drain plug (exhaust side)
8 Central plug for electrical system
9 Voltage regulator
10 Coolant supply to engine
11 Coolant return to radiator and thermostat
12 Temperature switch
13 Exhaust manifold
14 Connector for vent line to expansion tank
(coolant)
15 Cylinder head cover
3
4
5
6
7
1
2
14
12
11
10
9
8
15
13
4Exhaust side