Hatz Diesel 2 - 4 L 40 Instruction Book
INSTRUCTION BOOK
43340205-ENG-09.02-2
Printed in Germany
33
2-4L40.
2-4L41.
2-4M40.
2-4M41.
A new HATZ Diesel engine - working for you
This engine is intended only for the purpose determined 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 accepts no warranty. 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.
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 maintenance 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.
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 engine 5
3. General information 7
3.1. Technical data
3.2. Transport
3.3 Installation instructions
3.4. Load on engine
3.5. Type plate
4. Operation 8
4.1. Before initial start-up
4.2. Starting the engine
4.3. Stopping the engine
5. Maintenance 14
5.1. Maintenance summary
5.2. Maintenance every 8 - 15 hours of operation
5.3. Maintenance every 250 hours of operation
5.4. Maintenance every 500 hours of operation
5.5. Maintenance every 1000 hours of operation
6. Operating checks and repair work 23
6.1. Checking operation of air cleaner maintenance indicator
6.2. Renewing fan drive belt, checking operation of belt monitor
7. Malfunctions – causes and remedies 25
8. Work on the electrical system 29
9. Protective treatment 29
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.
2
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 applicable 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 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 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 Servicestation, 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...4L40C, 2...4L40CH, 2...4L41C, 4L40K, 4L41K
5
1
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 Cover plate, control side
10 Oil drain plug
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
2
Description of engineExécution standard
Standard version
Engine 2...4 M 40 H / L / HZ / LZ • 2...4 M 41 • 2 ...4M 41 Z
6
3
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
4
3. General information
3.1. Technical data
2L40. 3L40. 4L40.
2L41. 3L41. 4L41.
2M40. 3M40. 4M40.
2M41. 3M41. 4M41.
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
Version H / L approx. 223 255 291
Version Z / HZ / LZ kg 228 262 306
Version C / K 276 331 396 / 386
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.
7
3.2. Transport
A suspension lug is provided as stand-
ard equipment, so that the engine and
its auxiliaries can be lifted safely. It is not
suitable for lifting complete machines or similar to which the engine has been attached, and
this is strictly prohibited. (See Chapter 2.)
3.3. Instructions for installation
The „Manual for Selection and Installation of
Engines“ 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.
3.4. Load on engine
Operating the engine for a lengthy period offload or at very low loads can affect its running
quality.
We therefore recommend a minimum engine
load of 15 %. If operated at such low loads, it is
best to operate the engine at a significantly higher load for a short period before switching it off.
3.5. Type plate
The type plate is placed on the crankcase resp.
on the capsule (chapt. 2) and includes the following engine information (pict. 5a resp. 5b):
engine type
code (only for special equipment)
engine number
max. engine speed
For any offer as well as spare part orders it is
necessary to mention these data (also see spare
parts list, page 1).
4. Operation
4.1. Before first start-up
Engines are normally delivered without any fuel
or oil.
4.1.1. Engine oil
All brand-name engine oils which comply with
the minimum requirements of the following
specifications are suitable:
CCMC D4 / D5 / PD2 or
API CD / CE / CF / CG or
SHPD
If engine oils with low quality standard are being
used, the intervals of changing the engine oil
have to be reduced from 250 to 150 resp. 500 to
250 hours of operation, see chapter 5.1.
Oil viscosity
Choose a suitable oil viscosity according to the
ambient temperature when the engine is started
from cold (Figure 6).
Engine oil quantities and dipstick markings
dipstick
Engine type Sump
Oil content marking
(liter) (Figure 7,
item 2)
2L40C/CH
2L41C Yes 7.5 C
2M40 HZ /LZ No 4.5 A
2M41 Z
2M40 H /L
Yes 8.5 C
No 5.5 A
2M41
Yes 8.5 C
No 5.5 A
3L40C/CH
3L41C Yes 10.5 D
3M40 HZ /LZ No 8.0 A
3M41 Z
8
dipstick
Engine type Sump
Oil content marking
(liter) (Figure 7,
item 2)
3M40 H /L
Yes 11.0 D
No 8.5 A
3M41
Yes 11.0 D
No 8.5 A
4L40C/CH
4L41C Yes 13.0 D
4M40 HZ /LZ No – –
4M41 Z
4L40 / 41 K
Yes 14.0 D
4M40 H /L
No – –
4M41
Note:
The engine oil contents stated here are to be re-
garded as approximate.
In all cases, the MAX marking on the dipstick
should be complied with.
The engine should be in a horizontal position
before adding oil or checking the oil level.
–Pull out dipstick „1“ (fig. 7).
–Add engine oil up to the MAX mark on dipstick
„1“ (Figures 7 and 8).
– Run the engine for a short time, then check oil
level again and correct if necessary.
4.1.2. Fuel
Stop the engine before refilling the
fuel tank. Never refuel near a naked
flame or sparks which could start a fire. Don't
smoke. Use only pure fuel and clean filling
equipment. Take care not to spill fuel.
All diesel oils sold as fuel and complying with
the following minimum specifications can be
used:
EN 590 or
DIN 51601 - DK or
BS 2869 A1 / A2 or
ASTM D 975 - 1D / 2D
– Before the engine is first started, or if the fuel
system was run dry, prime the fuel delivery
pump at lever „1“ until fuel is heard to flow
back through the return line „2“ to the fuel
tank (Figure 9).
Important !
Remember to replace the access cover for the
fuel delivery pump in the side panel of the engine enclosure after priming the pump (Chap. 2).
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 %
9
4.2. Starting
Do not run the engine in closed or
badly ventilated rooms – danger of
poisoning! Before the engine is started, always
make sure that nobody is in the danger area
(moving parts on engine or machinery) and
that all safety guards are in place.
Never use any spray starting aids (Fig. 10)
If possible, disengage the engine from any
driven equipment.
The auxiliary equipment should always be placed
in neutral.
4.2.1. Starting with the electric starter
–Move the speed control lever to the 1/2 START
or max. START position, according to requirements and starting conditions (Figure 11).
Note that a lower speed setting will cause less
exhaust smoke when starting.
– Insert start key and turn to position I (Fig. 12).
– Battery charge telltale „2“ and oil pressure
warning „3“ must light up (Fig. 13).
– Turn start key to position II (Fig. 12).
– 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 air cleaner maintenance indicator „5“ only
lights up during operation if the air cleaner ele-
ment needs to be cleaned or renewed (Fig. 13,
see chapter 5.4.2.).
– 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.
– 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 installed, the
start key has to be returned to position 0 for at
least 8 seconds after the engine has failed to
start or after switching it off before a further
attempt can be made to start the engine.
Preheating device with automatic heating
timer (additional equipment)
The preheating light „6“ lights up additionally at
temperatures below 0° Celsius (Fig. 13).
– After the light has gone out, start the engine
without delay.
Automatic shut-down function
(additional equipment)
Engines with the automatic shut-down function
have the preheating display „6“ on the instrument box, see figure13.
Important!
If the engine cuts out immediately after starting
or switches off by itself during operation, a
monitoring element in the automatic shutdown
system has tripped. The corresponding indicator
light (Fig. 13, positions 2 - 5) will come on.
After the engine has stopped, the display continues to glow for about 12 seconds.
The electrical device then switches itself off automatically. The display lights up again after the
start key has been turned back to position 0 and
then to position I again.
Trace and eliminate the cause of the operating
fault before trying to restart the engine (see
chapter 7).
The display light goes out when the engine is
next started.
Even with automatic shutdown monitoring the
oil level must be checked every 8 – 15 operating hours (Chapter 5.2.1.).
10
4.2.2. Emergency starting
If the engine has been stopped by the automatic
shutdown system because of an electrical fault
signal or inadequate oil pressure, an emergency
start can be attempted, though in this case the
manufacturer will accept no liability for consequential damage.
An emergency start could for example be unavoidable if the engine is used to power a vehicle which has come to a halt in a potentially
dangerous area (for example on a rail crossing
or road junction).
Proceed as follows:
– Detach the hood of enclosure „13“ (Figure 2)
or side panel „2“ (Figure 3).
– Place a suitable tool, for example a screw driv-
er, behind emergency start lever „2“ and pull
sharply outwards. This will break the lead seal
„3“ between the emergency start lever and the
screw on the engine block (Figure 14).
– As soon as the emergency start lever is in the
starting position, the engine can be started
again.
Important:
If the emergency start lever is used, the automatic shutdown system ceases to operate and the
warranty is invalidated. For this reason, run the
engine only in a genuine emergency and for a
very short time (a few seconds) after operating
the emergency start lever. Make sure before restarting the engine that there is sufficient oil in
the engine; if oil pressure is too low, irreparable
engine damage may occur very quickly.
Immediately after running the engine in an emergency, locate the origin of the fault signal and
rectify the fault (see Chapter 7).
If any problems arise, please contact the nearest
HATZ service point.
4.2.3. Starting with handle
(on 2-4 M 40. / 2-4 M 41 engines only)
Preparations
– Move the speed control lever to START posi-
tion (Fig. 11).
– Turn all decompression levers (1 on two-cylin-
der engines, 3 on three-cylinder engines, 4 on
four-cylinder engines) to position 1 (Fig. 15).
Important !
Turn decompression levers only in the direction
shown by the arrow.
Exception:
the lever can be moved back directly from position „1“ to „0“.
Never operate the automatic decompression system when the engine is
running.
– Check that the starting handle is in correct
working order, without a broken tubular handle
worn engagement dogs or similar faults.
– Lightly grease the sliding-contact area between
the starting handle and the guide sleeve.
– Insert the starting handle, hold it with both
hands and stand in the correct position in
relation to the engine (Figure 16).
– Turn the engine over until it is felt to move
more freely.
2M40./2M41 two-cylinder engines
– Turn the decompression lever to position „2“
(Figure 15).
3M40./3M41 three-cylinder engines
–Turn the decompression levers for cylinders 1
and 3 (counting from the fan end) to position
„2“ (Figures 15 and 34).
–Turn the decompression lever for cylinder 2 to
position „3“.
11
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