Hatz Diesel 2G40, 2G40 H Operator's Manual
CRE ATI NG POW ER SOL UTI ONS .
INCLUDES SUPPLEMENTAL INFORMATION TO
THE OWNER’S MANUAL FOR MODEL YEAR 2017
EPA CERTIFIED NONROAD COMPRESSION-IGNITION ENGINES.
INCLUDES SUPPLEMENTAL INFORMATION FOR
THE USE OF EPA CERTIFIED ENGINES WITHIN
CALIFORNIA.
2G40 | 2G40 H
OPERATOR’S MANUAL
Diesel engine
Hatz Diesel
www.HATZ-DIESEL.com
2G40, 2G40 H Table of contents
Table of contents
1 Notices .................................................................................................................5
2 General information ............................................................................................ 6
3 Safety ................................................................................................................... 7
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
General information .............................................................................................................7
Intended use and foreseeable misuse................................................................................. 7
Machine user or machine manufacturer obligations ............................................................ 8
Representation of safety notes ............................................................................................ 9
Meaning of safety symbols ................................................................................................10
Safety notes....................................................................................................................... 12
Operational safety.............................................................................................................. 12
Machine-specific safety instructions for operation ............................................................. 15
Machine-specific safety instructions for maintenance work............................................... 16
Electrical equipment ..........................................................................................................18
Labels ................................................................................................................................19
4 Technical data ................................................................................................... 20
4.1
4.2
4.3
4.4
4.5
Engine information and filling quantities ............................................................................20
Engine type plate ............................................................................................................... 21
Physical operating conditions ............................................................................................22
Engine oil ........................................................................................................................... 22
Fuel.................................................................................................................................... 23
5 Engine overview................................................................................................ 25
5.1
Designation of components ...............................................................................................25
6 Transport, assembly and commissioning ...................................................... 27
6.1
6.2
6.3
6.4
6.5
Transport ...........................................................................................................................27
Installation notes................................................................................................................ 28
Preparations for commissioning ........................................................................................29
Filling engine oil (first filling)............................................................................................... 29
Filling the oil bath air filter (option)..................................................................................... 31
7 Operation and use............................................................................................. 32
7.1
7.2
7.3
7.3.1
7.3.2
7.4
7.5
7.5.1
7.5.2
7.6
7.6.1
Safety notes....................................................................................................................... 32
Performing tests................................................................................................................. 33
Start preparation ................................................................................................................ 34
Pumping fuel with the manual lever................................................................................... 34
Setting the speed control ................................................................................................... 35
Starting the engine............................................................................................................. 36
Switching off the engine..................................................................................................... 40
Switching off the engine (mechanical) ............................................................................... 40
Switching off the engine (electrical) ................................................................................... 42
Check the oil level.............................................................................................................. 43
Engine oil level................................................................................................................... 44
HATZ
3Operator’s Manual
Table of contents 2G40, 2G40 H
7.6.2
7.7
7.8
8 Maintenance ...................................................................................................... 49
8.1
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.2.8
8.2.9
8.2.10
8.2.11
9 Faults.................................................................................................................. 72
9.1
10 Storage and disposal........................................................................................ 77
10.1
10.2
11 Declaration of incorporation ............................................................................ 80
Oil level in the oil bath air filter (option).............................................................................. 45
Refueling............................................................................................................................ 46
Check the air filter warning indicator (option) ....................................................................48
General maintenance instructions .....................................................................................49
Maintenance work.............................................................................................................. 50
Maintenance notice label ................................................................................................... 50
Maintenance plan ..............................................................................................................51
Check the intake area of the combustion air .....................................................................53
Checking the cooling air area ............................................................................................55
Change the engine oil and oil filter ....................................................................................56
Cleaning the oil bath air filter .............................................................................................60
Checking and setting the tappet clearance........................................................................ 62
Cleaning the cooling air area ............................................................................................. 64
Checking the screw connections .......................................................................................67
Changing the fuel filter....................................................................................................... 67
Maintaining the dry air filter................................................................................................ 69
Trouble shooting ................................................................................................................ 72
Storing the machine........................................................................................................... 77
Disposing of the machine ..................................................................................................79
12 EPA CERTIFIED ENGINES................................................................................ 81
13 EPA CERTIFIED ENGINES WITHIN CALIFORNIA........................................... 89
4
Operator’s Manual
HATZ
2G40, 2G40 H Notices
1 Notices
Contact data
© 2017
Motorenfabrik HATZ
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. +49 (0)8531 319-0
Fax +49 (0)8531 319-418
marketing@hatz-diesel.de
www.hatz-diesel.com
All rights reserved!
Copyright
The copyright for this manual rests entirely with Motorenfabrik HATZ, Ruhstorf.
This manual may only be copied or distributed if written approval has been
received. This also applies to the copying or distribution of excerpts of this
manual. The same conditions apply to distribution of this manual to third parties in digital form.
Original manual
This manual has been translated into multiple languages.
The German version is the original manual. All other language versions are
translations of the original manual.
HATZ
5Operator’s Manual
General information 2G40, 2G40 H
2 General information
Information on the document
This manual was created with due care. It is exclusively intended to offer a
technical description of the machine and to provide instructions on commissioning, operating and maintaining the machine. When operating the machine, the applicable standards and legal regulations as well as any in-house
regulations apply.
Before commissioning, during operation and before maintenance work is begun on the machine, read this manual carefully and keep it close by for
ready access.
Machine
This manual describes the following machine.
Machine name HATZ diesel engine
Type number 2G40, 2G40 H
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the over 500 HATZ service stations. Trained specialists there will repair your machine with Hatz original spare parts and
with HATZ tools. The global HATZ service network is at your disposal to advise you and supply you with spare parts. For the address of the Hatz ser-
vice station nearest you, please see the enclosed spare parts list or visit us
in the Internet at: www.hatz-diesel.com
Installation of unsuitable spare parts can lead to problems. We cannot accept responsibility for direct damage or secondary damage that results from
this.
We therefore recommend the use of Hatz original spare parts. These parts
are manufactured according to strict Hatz specifications and achieve maximum operational reliability through their perfect fit and functionality. The order number can be found in the enclosed spare parts list or on the Internet
at: www.hatz-diesel.com
Exclusion of liability
The manufacturer cannot be held responsible for personal injury, damage to
property or damage to the machine itself caused by improper use, foreseeable misuse, or failure to follow or adequately follow the safety measures
and procedures described in this manual. This also applies to changes made
to the machine and the use of unsuitable spare parts.
Modifications, which serve the technical improvements, are reserved
6
Operator’s Manual
HATZ
2G40, 2G40 H Safety
3 Safety
3.1 General information
Introduction
This chapter contains the information you need to work safely with this machine.
To prevent accidents and damage to the machine, it is imperative that these
safety instructions be followed.
Read this chapter carefully before beginning work.
3.1.1 Intended use and foreseeable misuse
Intended use
The machine described in this manual fulfills the following functions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See chapter 11 Declaration of incorpo-
ration, page 80.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine in which the engine is installed.
Any other use is not intended and therefore not permitted. Violations compromise the safety of the personnel working with the machine. Motorenfabrik
HATZ does not accept any liability for damage resulting from this.
The operational safety of the machine is only guaranteed if it is used as intended.
The intended use also includes observance of the instructions in this Operator's Manual to preserve the environment, including in the appendix for the
model year 2017 as per EPA Nonroad Diesel Engines.
HATZ
Foreseeable misuse
The following is considered to be foreseeable misuse:
▪ Any use that varies from or extends beyond the uses specified above.
▪ Failure to comply with the instructions given in this manual.
▪ Failure to comply with the safety instructions.
▪ Failure to immediately eliminate malfunctions that impact safety before
continuing work with the machine (working with the machine when it is not
in perfect condition, either functionally or in terms of safety).
▪ Failure to perform the necessary inspection and maintenance work.
▪ Any unauthorized modification of or removal of safety equipment.
▪ Use of spare parts and accessories that are unsuitable or have not been
approved by HATZ.
▪ Operation in flammable or hazardous environments.
▪ Operation in closed-off or poorly ventilated rooms.
7Operator’s Manual
Safety 2G40, 2G40 H
▪ Installation of the machine in mobile equipment (e.g. vehicles, trailers) or
in closed rooms without additional measures to handle supply air, extract
air, and exhaust gas.
▪ Improper operation at variance with DIN6271 and DINISO8528 (climate,
load, safety).
Residual risks
Residual risks result during daily use and in association with maintenance
work.
These residual risks will be pointed out in chapter 3.2.2 Machine-specific
safety instructions for operation, page 15 and in chapter 3.2.3 Machinespecific safety instructions for maintenance work, page 16 as well as in the
further contents of the manual, directly in front of the descriptions or operating instructions concerned.
3.1.2 Machine user or machine manufacturer obligations
Machine manufacturer obligations
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine. These assembly instructions contain important information on how to safely install the engine and are available at your nearest HATZ service station.
It is prohibited to start the engine before it is fully installed.
In addition, please note that it is prohibited to start up the machine before it
has been determined that the machine into which this engine is installed fulfills all safety-related requirements and legal regulations.
User obligations
The operator is obliged to only operate the machine when it is in perfect condition. The operator must check the condition of the machine before use and
ensure that any defects are eliminated before it is taken into service. Running the machine while identified defects exist is not permitted. The user
must also ensure that all persons who work on the machine are familiar with
the contents of this manual.
8
Operator’s Manual
HATZ
2G40, 2G40 H Safety
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood this manual or must possess the qualifications necessary for working with this equipment, acquired in training/instructional courses. No one may work with the machine without the necessary qualifications,
even if for just a brief period.
The operating personnel must not be under the influence of drugs, medication or alcohol.
All work performed on the machine must be in compliance with the information provided in this manual.
Storing this manual
This manual is an integral component of the machine (also when being
sold). It must be stored in the direct vicinity of the machine and be accessible to personnel at all times.
3.1.3 Representation of safety notes
Overview
This machine has been designed and built according to state-of-the-art technology and the recognized safety standards. Despite these precautions,
risks exist when operating the machine and during maintenance work.
These risks are identified in this manual by means of safety notes.
The safety notes precede the related description or operating step.
HATZ
Structure of the safety notes
The safety notes consist of:
▪ Danger symbol
▪ signal word
▪ Description of danger
▪ Possible consequences
▪ Preventative measures
General danger symbol
The general danger symbol is used to identify the danger of personal injury.
9Operator’s Manual
Safety 2G40, 2G40 H
DANGER
WARNING
CAUTION
CAUTION
NOTICE
Signal words
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
Danger symbol/
signal word
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this manual.
Symbol Meaning
Smoking, fire, and open flames are prohibited!
Meaning
This signal word is used to indicate imminently
dangerous situations which, if not avoided, will
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to minor or moderate injury.
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
This signal word indicates additional useful information, such as operating tips and cross references.
10
Warning of personal injury!
Warning of hot surfaces!
Warning of flammable substances!
Operator’s Manual
HATZ
2G40, 2G40 H Safety
i
Symbol Meaning
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
Warning of heavy loads!
Warning of environmental damage!
Comply with this manual or additional documentation from
other manufacturers or the carrier.
HATZ
Additional information that is useful to the reader.
11Operator’s Manual
Safety 2G40, 2G40 H
3.2 Safety notes
3.2.1 Operational safety
Introduction
This chapter contains all of the important safety instructions for personal protection and for safe and reliable operation. Additional, task-related safety instructions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury or danger of property damage due to failure to comply with this manual and the safety
instructions contained therein.
▪ As the operator of the machine, you must ensure that all
people working on the machine are familiar with the content
of this manual.
▪ Before working on the machine, read this manual carefully,
paying special attention to the safety notes.
▪ Fulfill all required safety conditions before working on the
machine.
▪ Follow all general safety instructions as well as the specific
task-related safety instructions contained in the individual
chapters.
12
Using the machine
▪ Only operate the machine for the purposes described in chapter 3.1.1 In-
tended use and foreseeable misuse, page 7.
Compliance with other regulations
▪ Adhere to the applicable accident prevention regulations of the trade asso-
ciations.
▪ Comply with the regulations concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regula-
tions also apply when operating the machine.
Personal protective equipment
During operation and maintenance of the machine, personal protective
equipment must be available and must be used if necessary. The required
personal protective equipment is specified in the descriptions of the operating steps.
Operator’s Manual
HATZ
2G40, 2G40 H Safety
Personal protective
equipment
Safety shoes Safety shoes offer protection
Hearing protection Hearing protection offers protec-
Safety gloves Safety gloves protect the hands
Safety goggles
(with side protection)
Working clothes Wear close-fitting clothing. How-
Warning labels and information signs on the machine
The warning labels and information signs on the machine must be followed
(see chapter "Labels" 3.3 Labels, page 19).
The warning labels and information signs must be kept legible and must be
replaced if necessary. For this purpose, contact your nearest HATZ service
station.
Pictogram Function
against:
▪ Slipping
▪ Falling objects
tion against ear injuries due to
excessive and constant noise.
against injury, e.g. from battery
acid.
Safety goggles protect the eyes
from flying objects (e.g. dust
particles, spraying liquids, spraying acid).
ever, it must not restrict the
wearer's freedom of movement.
HATZ
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians (see chapter 2 General in-
formation, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.
Safety equipment
Safety equipment must not be modified and must not be rendered ineffective
during normal operation.
13Operator’s Manual
Safety 2G40, 2G40 H
General safety instructions
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in this manual.
▪ Heed the warnings on the machine and in this manual.
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪ The personnel must have read and understood this manual
or must possess the qualifications necessary for working
with this equipment, acquired in training/instructional courses.
▪ Only qualified personnel is permitted to operate and main-
tain this machine.
▪ Failure to comply will cause the warranty to become void.
WARNING
Danger of injury from failure to follow the operating instructions and from performing unauthorized tasks on the machine.
▪ Follow all instructions.
▪ Do not perform activities for which no qualification is avail-
able. Contact properly trained personnel if necessary.
14
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist (see chapter 6.1 Transport,
page 27).
Operator’s Manual
HATZ
2G40, 2G40 H Safety
3.2.2 Machine-specific safety instructions for operation
Introduction
The machine can pose residual risks during operation. To eliminate these
risks, all persons working on the machine must follow the general and machine-specific safety instructions.
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine.
These assembly instructions contain important information on safe installation.
If the engine is installed in a machine or assembled with other machines to
form a machine, it is prohibited to start the engine before it has been determined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations.
Safe operation
▪ Before switching on the machine, ensure that no one can be injured when
the machine is started up.
▪ During machine operation, ensure that unauthorized persons do not have
access to the area in which the machine has an impact.
▪ Parts of the exhaust gas system and the surface of the engine become hot
during operation. Risk of injury from touching hot parts! Let the engine cool
before maintenance.
▪ Do not refuel during operation.
HATZ
Faults
▪ Immediately eliminate faults that compromise safety.
▪ Switch off the machine and do not take into service again until all faults
have been eliminated.
Safety instructions for operation
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
15Operator’s Manual
Safety 2G40, 2G40 H
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
3.2.3 Machine-specific safety instructions for maintenance work
Introduction
The machine can pose residual risks during maintenance. To eliminate
these risks, all persons working on the machine must follow the general and
machine-specific safety instructions.
Maintenance intervals
▪ Strictly adhere to the maintenance intervals.
Regular maintenance according to the instructions in this manual is essential for ensuring reliable operation and the correct engine exhaust quality.
▪ Check the safety equipment regularly to ensure it is in good condition and
functioning properly.
▪ Check connections, cables and fasteners regularly to ensure they are in
good condition.
16
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians. We recommend that you
work with one of the over 500 HATZ service stations.
Replacing parts
▪ When replacing defective components, we recommend that you use gen-
uine HATZ original spare parts (see chapter 2 General information, page
6).
▪ When disposing of parts that can no longer be used, do so in accordance
with local environmental regulations or send them to a recycling center.
Measures following maintenance and troubleshooting
▪ Securely reconnect loose electrical connections; check that the electrical
components and equipment are functioning properly.
▪ Check the entire machine for foreign bodies; remove any foreign bodies.
Operator’s Manual
HATZ
2G40, 2G40 H Safety
Safety instructions for maintenance work
DANGER
Danger of explosion from flammable cleaning agents.
Cleaning with benzene is an explosion hazard. It is highly
flammable, can become electrostatically charged, and can generate an explosive gas/air mixture.
▪ Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
▪ Comply with manufacturer's instructions.
WARNING
Danger of injury from compressed air and dust particles.
Eye injuries may occur when cleaning with compressed air.
▪ Wear safety goggles.
CAUTION
HATZ
Danger of injury if maintenance instructions are not followed.
▪ Only perform maintenance when the engine is switched off.
▪ Protect start-up devices (crank handle, recoil start or start-
ing key) from unauthorized access.
▪ For engines with a starter: Disconnect the negative battery
terminal.
▪ When the maintenance work has been completed, ensure
that all tools are removed from the machine.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
17Operator’s Manual
Safety 2G40, 2G40 H
3.2.4 Electrical equipment
Safety notes
DANGER
Danger to life, danger of injury or danger of property damage due to incorrect use of batteries.
▪ Do not place tools or other metal objects on the battery.
▪ Before performing work on the electrical equipment, always
disconnect the negative battery terminal.
▪ Never swap the positive (+) and negative (–) battery termi-
nals.
▪ When installing the battery, first connect the positive cable
and then the negative cable.
▪ When removing the battery, first disconnect the negative
cable and then the positive cable.
▪ It is imperative to prevent short circuits and mass contact of
current carrying cables.
▪ If faults occur, check the cable connections for good con-
tact.
DANGER
18
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪ Keep batteries away from open flames and incendiary
sparks.
▪ Do not smoke when working with batteries.
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
▪ Protect your eyes, skin, and clothing from corrosive battery
acid.
▪ Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.
Operator’s Manual
HATZ
2G40, 2G40 H Safety
2G40
= 1h
max
OIL
OIL
0,1 mm
0.004"
max
0000 040 096 02
500h
250h
BIO
DIESEL
052 356 02
0000 053 657 02
NOTICE
▪ The necessary wiring diagrams are included with the ma-
chine if it is equipped with electrical equipment. Additional
wiring diagrams can be requested when needed.
▪ We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
▪ Promptly replace faulty indicator lamps.
▪ Do not pull out the starting key during operation.
▪ Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪ When cleaning, do no spray the electrical equipment components with a
water jet or high pressure cleaner.
▪ When performing welding work on the machine, disconnect the battery
and place the ground clamp of the welding equipment as close as possible
to the welding area. Disconnect the plug-in connection to the voltage regulator.
3.3 Labels
Warning labels and information signs on the engine
Label Meaning
Maintenance instructions (see chapter 8.2.2 Maintenance plan, page
51
HATZ
Refuel with diesel fuel only. For the
specification, see chapter 4.5 Fuel,
page 23.
Do not use bio diesel.
The engine may only be operated
with fuel that is "EXTREMELY LOW
IN SULFUR OR SULFUR-FREE".
The fuel label is located close to the
fuel cap. If there is no fuel tank installed on the engine, the label must
be applied permanently close to the
fuel filler opening.
19Operator’s Manual
Technical data 2G40, 2G40 H
4 Technical data
4.1 Engine information and filling quantities
Type 2G40, 2G40 H
Type Air cooled, four stroke diesel engine
Combustion system Direct injection
Number of cylinders 2
Bore/stroke mm 92 / 75
Displacement cm
Engine oil capacity
without oil sump
With oil sump
Difference between the
"max." and "min."
marks
Engine oil consumption
(after running-in period)
Engine oil pressure Min. 1.0bar at 900rpm
Sense of rotation on
power take-off side Left
Tappet clearance
at 10 - 30°C
inlet/outlet mm 0.10
Max. perm. continuous
sloping position in the direction:
Exhaust low
Exhaust high
Flywheel low
Flywheel high
Weight Approx.
Battery capacity Min/max 12V – 45 / 88Ah
Version H: with power take-off for the operation of hydraulic pumps
1)
These values are approximations only. The max. mark on the dipstick is
decisive in any case (see section 7.6 Check the oil level, page 43).
2)
Exceeding these limit values causes engine damage!
3
Approx.
L.
Approx.
997
2.5
3.0
0.8
1)
1)
1)
L.
Approx. 1% of fuel consumption, pertaining to full load
without
oil sump
2)
30
2)
17
2)
25
2)
25
with
oil sump
2)
30
2)
17
2)
30
2)
25
106
kg
24V – 36 / 55Ah
20
Operator’s Manual
HATZ
2G40, 2G40 H Technical data
VARIABLE SPEED. ULTRA LOW SULFUR FUEL ONLY.
Power Category:
EMISSION CONTROL SYSTEM INFORM.:
4.2 Engine type plate
The layout of the EPA/CARB type plate depends on the engine application
and is affixed to the air guide housing.
It contains the following information:
1 EPA/CARB engine family number
2 Engine type, customer specification and setting of pumping start (°
crankshaft before top dead center)
3 Engine serial number
4 Max. engine speed (rpm)
5 Model year
6 Displacement (liters) and inspection requirement for special settings
7 Injection pump effective stroke (mm) and engine capacity
8 Information on exhaust control system
9 “variable speed" or "constant speed only" (if necessary)
The type plate also defines the applicable emissions-related performance
class of the engine.
The figure shows an EPA/CARB type plate.
A text that refers to the exhaust legislation and corresponds to the engine
type is printed on the type plate (EPA or EPA and CARB).
Every engine is equipped with an additional unattached type plate. When the
engine is built into a machine and the original type plate is not readily visible,
the second unattached type plate must be affixed to the application in a position that is clearly visible for an average person.
The following data must always be specified in case of queries and for spare
parts orders:
HATZ
21Operator’s Manual
Technical data 2G40, 2G40 H
i
2 Engine type/specification (only for special equipment)
3 Engine serial number
4 Max. engine speed (rpm)
Always install the engine appropriate for the intended application to fulfill the
EPA and CARB exhaust requirements.
4.3 Physical operating conditions
Engine adjustment
The engine is normally adjusted to operate within the standard reference
conditions stipulated in ISO3046-1:
Parameter Unit Value
Intake air temperature °C +25
K 298
Relative humidity % 30
Air pressure
(at approx. 100 meters above sea
level)
kPa 100
NOTICE
If the machine is operated at high altitudes and high temperatures, adjustment of the engine setting may be necessary if the
climatic conditions were not taken into account when the machine was ordered. If this is the case, please contact your nearest HATZ service station.
4.4 Engine oil
Oil quality
22
All oil brands that meet at least one of the following specifications are suitable:
▪ ACEA – B3 / E4 or better
▪ API – CF / CH-4 or better
If engine oils of a low quality standard are used, the oil change interval must
be reduced to 150 operating hours.
Operator’s Manual
HATZ
2G40, 2G40 H Technical data
-40
-30
-20
-10
0
10
20
30
40
50
104
86
68
50
32
14
-4
-22
-40
OIL : SAE .. .
°C°F
5W/ 30
5W/ 40
10
W/
4
0
10W /3
0
15 W
/
40
30
40
122
10
W
Oil viscosity
Choose the recommended viscosity based on the type of start (recoil,
crankhandle or electric) and on the engine temperature at which the engine
will be operated.
CAUTION
Engine damage from unsuitable engine oil.
Unsuitable engine oil considerably reduces engine service life.
Only use engine oil that fulfills the specifications stipulated
above.
4.5 Fuel
HATZ
Fuel type
All types of diesel fuel that meet the minimum requirements of the following
specifications are suitable:
▪ Europe: EN 590
▪ UK: BS 2869 A1 / A2
▪ ASTM D 975-09a 1-D or 2-D
CAUTION
Danger of engine damage from low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪ The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
23Operator’s Manual
Technical data 2G40, 2G40 H
CAUTION
Danger of malfunctions due to old fuel.
When diesel fuel is stored in a fuel tank or canister for lengthy
periods, deposits may form on account of fuel aging. These deposits result in malfunctions due to clogged fuel filters and damage to the injection system.
▪ Perform the prescribed storage steps in machines that will
be out of use for more than three months (see section 10.1
Storing the machine, page 77).
▪ Only refuel with fresh diesel fuel such as can be obtained
from filling stations.
Winter fuel
When outside temperatures drop below 0°C, use winter fuel or mix in petroleum in advance:
Lowest ambient temperature at start [°C]
0 to -10
-10 to -15
-15 to -20
-20 to -30
Percentage of petroleum [%]for
Summer fuel Winter fuel
20
30
50
‑
‑
‑
20
50
24
Operator’s Manual
HATZ
2G40, 2G40 H Engine overview
5 Engine overview
5.1 Designation of components
Overview
HATZ
1 Fuel line (feed pump - injection pump)
2 Air guide panel
3 Dipstick
4 Fuel return line
5 Injector
6 Lifting eye
7 Starter
8 Air guide
9 Air intake pipe
10 Type plate
11 Glow plug (option)
12 Oil bath air filter
13 Oil pressure switch
14 Rain cap
15 Oil filler plug
16 Fuel pressure tube
25Operator’s Manual
Engine overview 2G40, 2G40 H
17 Cylinder head cover
18 Oil line
19 Exhaust manifold
20 Injection pump
21 Stop lever
22 Speed control lever
23 Fuel feed pump
24 Oil filter
25 Oil drain screw
26 Protective grid
27 Air guide housing
28 Plug connection
29 Voltage controller
30 Engine mount
31 Crankshaft – power take-off (pto)
32 Fuel line (fuel filter - feed pump)
33 Fuel filter
26
Operator’s Manual
HATZ
2G40, 2G40 H Transport, assembly and commissioning
6 Transport, assembly and commissioning
6.1 Transport
Safety notes
WARNING
Danger of injury from improper lifting and transport.
Danger of crushing from falling or tipping of the engine.
▪ Only use the lifting eye already mounted on the machine for
lifting.
▪ Only use a suitable hoist with a sufficient carrying capacity.
▪ Do not remain under suspended loads.
CAUTION
Only use the lifting eye for transporting the engine.
Do not use for lifting the entire machine.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist.
HATZ
NOTICE
Danger of environmental damage from leaking fluid.
If the machine is tilted, engine oil and fuel can run out.
▪ Only transport the machine in an upright position.
27Operator’s Manual
Transport, assembly and commissioning 2G40, 2G40 H
Lifting point
Transport conditions
▪ When transporting the machine, follow the safety instructions.
▪ When transporting, follow the applicable safety and accident prevention
regulations of the trade associations.
▪ After delivery, check the machine for completeness and transport damage.
▪ Only transport the machine when it is switched off and has cooled down.
▪ If you have questions on transporting the machine, please contact your
nearest HATZ service station. For contact data, see chapter 1 Impres-
sum, page 5 or www.hatz-diesel.com.
6.2 Installation notes
HATZ diesel engines are efficient, robust, and have a long service life.
Therefore, they are usually installed in machines that are used for commercial purposes.
The machine manufacturer must follow the applicable regulations regarding
machine safety – the engine is a part of a machine.
Depending on the use and installation of the engine, it may be necessary for
the machine manufacturer and machine user to install safety equipment to
prevent inappropriate use. Note the following:
▪ Parts of the exhaust gas system and the engine surface become hot dur-
ing operation and may not be touched until they cool down after the engine is switched off.
▪ Incorrect cable connections and incorrect operation of the electrical equip-
ment can lead to sparking and must be avoided.
▪ After the engine is installed in the machine, rotating parts must be pro-
tected against contact.
HATZ safety equipment is available for the belt drive of the cooling fan and
alternator.
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Operator’s Manual
HATZ
2G40, 2G40 H Transport, assembly and commissioning
▪ Comply with all notices and warning labels on the engine and keep them
in a legible condition. If a label should become detached or difficult to
read, it must be replaced promptly. For this purpose, contact your nearest
HATZ service station.
▪ Any improper modification of the engine will result in a loss of liability cov-
erage for resulting damage.
Only regular maintenance, as specified in this manual, will maintain the operating readiness of the engine.
The assembly instructions contain important information on how to safely
assemble the engine. They are available from any Hatz service station.
If you have any questions, please contact your nearest HATZ service sta-
tion before commissioning the engine.
6.3 Preparations for commissioning
▪ Check the delivered parts for completeness, damage, and other noticeable
issues.
▪ Ensure that the setup location is adequately ventilated.
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
6.4 Filling engine oil (first filling)
Engines are normally delivered without an engine oil filling.
Safety notes
CAUTION
Danger of injury
Prolonged contact with engine oil can lead to irritation of the
skin.
▪ Wear safety gloves.
▪ If there is contact with the skin, thoroughly wash the af-
fected areas of the skin with soap and water.
HATZ
29Operator’s Manual
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