HATZ Diesel 2G40 H User Manual
2G40
2G40 H
33
0000 433 302 06 - ENG - 01.11 - 0.2
Printed in Germany
Translation of the
ORIGINAL INSTRUCTION BOOK
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 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.
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 following the strict HATZ specifications and ensure, thanks to their perfect fit and function, maximum operating 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
2
Page
1. Important notes on safe operation
of the engine 3
2. Description of the engine 5
3. General information 6
3.1. Technical data 6
3.2. Transport 7
3.3 Instructions for installation 7
3.4. Load on engine 7
3.5. Type plate 8
4. Operation 8
4.1. Before initial start-up 8
4.1.1. Engine oil 8
4.1.2. Oilbath air cleaner 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. Maintenance 14
5.1. Maintenace summary 14
5.2. Maintenance every 8 – 15
hours of operation 16
5.2.1. Check engine oil level 16
5.2.2. Check combustion air intake area 16
5.2.3. Check the cooling air system 17
Page
5.3. Maintenance every 250
hours of operation 18
5.3.1. Maintenance work on oilbath
air cleaner 18
5.3.2. Engine oil change and
oil filter renewal 18
5.3.3. Check and adjust vlave clearances 20
5.3.4. Clean the cooling air system 21
5.3.5. Check threaded connections 22
5.4. Maintenance every 500
hours of operation 22
5.4.1. Renew the fuel filter 22
5.4.2. Dry-type air cleaner maintenance 23
6. Functional test 24
6.1. Air filter maintenance indicators 24
7. Malfunctions – Causes – Remedies 25
8. Work on the electrical system 29
9 . Protective treatment 29
Declaration for Incorporation 30
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 notes on safe operation of the engine
HATZ diesel engines are economical, stronly built and long-lasting. They are therefore frequently
chosen for commercially and industrially operated equipment and machinery.
Since the engine forms part of the finished equipment or machine, its manufacturer will take all the
applicable safety regulations into account.
Nevertheless, we give below certain additional comments on operating safety, and would recommend
you to note them carefully.
Depend 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 against accidental contact when the engine is installed in other
equipment or machinery.
Guards are available from HATZ to protect belt drives to 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.
– 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
appropriate trainig.
– Keep the ignition 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 (safety data sheets).
3
Important notes on safe operation of the engine
– Stop the engine before performing any maintenance, cleaning- or repair work.
– Stop the engine before refuelling.
Never add fuel near a naked flame or a source of sparks.
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 a running engine.
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. In case a label has come off or is no longer clearly legible, it must be replaced immediately. To this effect, please contact the HATZ service station in your area.
– Note that any unauthorized modification to the engine absolves 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 the engine
5
Fig. 1
1 Fuel line (feed pump –
fuel-injection pump)
2 Air deflector
3 Oil dipstick
4 Fuel return line
5 Injector
6 Lifting eyebolt
7 Starter motor
8 Air guide
9 Air intake pipe
10 Type plate
11 Glow plug
(additional equipment)
12 Oilbath air cleaner
13 Oil pressure switch
14 Rainproof cap
15 Oil filler cap
16 Fuel pressure pipe
17 Cylinder head cover
18 Engine oil line
19 Exhaust manifold
20 Fuel injection pump
21 Stop lever
22 Speed control lever
23 Fuel feed pump
24 Engine oil filter
25 Oil drain plug
26 Guard
27 Air guide housing
28 Separable connector
29 Voltage regulator
30 Engine mount
31 Crankshaft, power-take-off
32 Fuel line
(fuel filter - feed pump
33 Fuel filter
3. General remarks
3.1. Technical data
Type 2G40 / 2G40H
Design Air-cooled four-stroke diesel engine
Combustion system Direct injection
Number of cylinders 2
Bore/stroke mm 92 / 75
Displacement cm³ 997
Engine oil content 2.5 excl. sump
1)
incl. filter renewal l. approx. 3.0 incl. sump
1)
Difference between
„max“ and „min“ levels l. approx. 0.8
1)
Engine oil pressure min. 1 bar at 900 r.p.m. engine speed
Engine oil consumption
(after running-in period) approx. 1% of fuel consumption at full load
Direction of rotation,
power take-off end anti-clockwise
Valve clearances at 10 - 30 °C
Inlet/exhaust mm 0.10
Max. permissible perm. inclination Exhaust Flywheel
Angle of inclination in ° low high low high
without oil sump 30
2)
17
2)
25
2)
25
2)
with oil sump 30 2)17
2)
30
2)
25
2)
Weight (incl. fuel tank, air-cleaner, kg
exhaust silencer and electric starter) approx. 106
Battery capacity min / max 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 breakdown.
6
3.2. Transport
2
The lifting eyebolt provided as stand-
ard equipment is intended for safe
movement of the engine.
It is not intended for lifting complete machinery to which the engine is attached, and this is
strictly forbidden.
3.3. Instructions for installation
If you have an engine which is not yet installed
in a machine and still has to be installed, make
sure that the Assembly Instructions for HATZ
Diesel Engines are complied with prior to installation. These Assembly Instructions contain important information about safe assembly of the
engine and are available from your the HATZ
service center in your area.
Pending complete installation, the engine
must not be started !
Moreover, we would like to point out that in this
case, commissioning of the machine is also prohibited until it has been verified that the machine
into which this engine is to be incorporated
complies with all the safety precautions and regulations provided by law.
Refer also to the Declaration for Incorporation
at the end of these Operating Instructions.
3
The permitted loads and elements on
the speed adjusting lever and the stop
lever should be observed as an exess can lead
to damage to the contacts and inner governor
parts.
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.
7
8
3.5. Type plate
4
The type plate is placed on the air guide (Fig. 1,
pos. 10) and includes the following engine information:
➀ engine type
➁ code (only for special equipment)
➂ engine number
➃ max. engine speed
For any offer as well as spare parts orders it is
necessary to mention these data (also see spare
parts list, page 1).
➀
➁
➂
➃
4. Operation
4.1. Before initial start-up
Engines are normally delivered without fuel and
oil.
4.1.1. Engine oil
Oil quality
Qualified are all trademark oils which fulfil at
least one of the following specifications:
ACEA – B2 / E2 or more significant
API – CD / CE / CF / CF-4 / CG-4 or more
significant.
If engine oil of a poorer quality is used, reduce
oil change intervals to 150 hours of operation.
Oil viscosity
5
Please select the recommended viscosity depending on the ambient temperature at which
the engine is operated.
Inappropriate engine oil may shorten the
engine’s service life significantly.
-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
10W/40
10W/30
15W/40
30
40
122
10 W
When adding oil or checking the level, the engine must be in a horizontal position.
6
– Remove oil filler screw „1“ and dipstick „2“.
– Add engine oil up to the max. mark on the
dipstick.
Lubricating oil capacity: see Chapter 3.1.
– Insert the oil filler screw and tighten it (hand-
tight only).
Attention !
If the engine is operated while the oil level is
below the min. mark or above the max. mark,
it can cause damage to the engine.
1
2
4.1.2. Oilbath air cleaner
7
If a cyclone-type dust trap is fitted, make sure
that the dust outlet is pointing in the correct
direction.
– Fill the oil tank up to mark „1“ with engine oil.
– Attach oil tank „2“, making sure that sealing
ring „3“ is correctly seated and clips „4“ are
fastened securely.
9
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