Hatz Diesel 2G 40 H Manuale utente

2G 40

2G 40 H

0000 433 302 06 -EN G -01.11 -0.2

Printed in Germany

Translation ofthe

ORIGINAL INSTRUCTION BOOK

A new HATZ Dieselengine -working foryou

This engine is intended only for the purpose determined and tested by the m anufacturer ofthe

equipm entin which itis installed.Using itin any other m anner contravenes the intended purpose.

For danger and dam age due to this,Motorenfabrik H ATZ assum es no liability. The risk is with the

useronly.

U se ofthis engine in the intended m anner presupposes com pliance with the maintenance and repair

instructions laid dow n for it.N oncom pliance leads to engine breakdow n.

Please do notfailto read thi

s operating manualbefore starting the engine.This willhelp you to avoid

accidents,ensure thatyou operate the engine correctly and assist you in com plying with the mainte-

nance intervals in orderto ensure long-lasting,reliable perfor

mance.

Please pass this Instruction M anualon to the next user orto the follow ing engine ow ner.

Alw ays have service work performedby qualified specialists.To this effect,werecom m end thatyou

consultone ofthe 500 HATZ service stations.There,your engine is repaired by staffw ho constantly

undergo training and who use both originalH ATZ spare part

s and H ATZ tools.The world-wide H ATZ

service network is also available to you for consultation and spare parts supply.

For the address ofyour nearest H ATZ service station,please refer to the attached list or the internet

under:www.hatz-diesel.com

The installation ofinappropriate spare parts maycause problem s.Wecannnotaccept any liability for

dam age or consequentialdam age resulting therefrom .

Thus,werecom m end thatyou use originalH ATZ spare parts. These parts are m anufactured follow -

ing the st

rict H ATZ specifications and ensure,thanks to theirperfect fitand function,maximum oper-

ating reliability. For the reference num ber,please consultthe attached spare partlist or the internet

under:www.hatz-diesel.com .

Please take the com plete spare parts kits in Table M 00 into account.

Wereserve the rightto m ake m odifications in the course oftechnicalprogress.

M OTORENFABRIK H ATZ GM BH & CO KG

Page

1. Im portantnotes on safe operation

ofthe engine 3

2. D escription ofthe engine 5

3. G eneralinformation 6

3.1. Technicaldata6

3.2. Transport7

3.3Instructions for installation 7

3.4. Load on engine 7

3.5. Type plate8

4. O peration 8

4.1. Before initialstart-up 8

4.1.1.Engine oil8

4.1.2.O ilbath aircleaner 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. M aintenance 14

5.1. M aintenace sum m ary14

5.2. M aintenance every 8 – 15

hours ofoperation 16

5.2.1.C heck engine oillevel 16

5.2.2.C heck com bustion airintake area 16

5.2.3.C heck the cooling airsystem 17

Page

5.3. M aintenance every 250

hours ofoperation 18

5.3.1.M aintenance work on oilbath

aircleaner 18

5.3.2.Engine oilchange and

oilfilter renew al 18

5.3.3.C heck and adjustvlave clearances 20

5.3.4.Clean the cooling airsystem 21

5.3.5.C heck threaded connections 22

5.4. M aintenance every 500

hours ofoperation 22

4.1.R enew the fuelfilter 22

5.4.2.D ry-type aircleaner maintenance 23

6. Functionaltest 24

6.1. Airfilter maintenance indicators24

7. M alfunctions – Causes – Rem edies 25

8. W ork on the electrical system 29

9 .Protective treatm ent 29

Declaration for Incorporation 30

Contents

This sym bolidentifies im portant safety precautions.

Please com ply with these mostcarefully in order to avoid any risk ofinjury to persons or

dam age to materials.

Generallegalrequirem ents and safety regulations issued by the com petent authorit

ies or

industrialaccidentinsurers mustalso be com plied with.

1. Im portantnotes on safe operation ofthe engine

HATZ dieselengines are econom ical,stronly builtand long-lasting.They are therefore frequently

chosen forcom m ercially and industrially operated equipm entand machinery.

Since the engine formspartofthe finished equipm entor machine,its m anufacturer willtake allthe

applicable safety regulations into account.

N evertheless,wegive below certain additionalcomments on operating safety, and w ould recom m end

you to note them carefully.

Depend on the m anner in which the engine is installed and it

s intended application,the equipm ent

m anufacturer or operator mayhave to attach additionalsafety devices and prohibitpotentially

hazardous aspects ofoperation,forexam ple:

– Exhaustsystem com ponents as wellas the surface ofthe engine willnaturally be hotand mustnot

be touched while the engine is running or untilithas cooled dow n after being stopped.

– Faulty wiring or incorrect operation ofelectricalequipm entmaylead to sparks forming,and must

be avoided as a potentialfire hazard.

– Rotating parts mustbe shielded againstaccidentalcontact whenthe engine is installed in other

equipm entor machinery.

Guards are available from H ATZ to protect beltdrives to cooling fans and generators.

– Before attem pting to startt

he engine itis essentialto have studied the starting information in the

instruction book.

– M echanicalstarting devices mustnotbe used by children or persons ofinsufficient physical

strength.

– Before starting the engine,ensure that

allthe specified protective guards are in place.

– The engine mustonly be operated,serviced orrepaired by persons who have received the

appropriate trainig.

– Keep the ignition key outofreach ofunauthorized persons.

– Do notrun the engine in cl

osed or badly ventilated room s.

Do notbreath in em issions – dangerofpoisoning!

– Also fueland lubricants could contain poisonous com ponents.Please follow the instructions ofthe

mineraloilproducer (safety data sheets).

Im portantnotes on safe operation ofthe engine

– Stop the engine before performing any maintenance,cleaning- or repairwork.

– Stop the engine before refuelling.

N ever add fuelnear a naked flam e or a source ofsparks.

Don'tsm oke.D on'tspillfuel.

– Keep explosive materials as wellas fl

ammable materials aw ay from the engine because the exhaust

gets very hotduring operation.

– Wearclose-fitting clothing when working on a running engine.

Please don'twearnecklaces,bracelets or any other things which you could getcaughtwith.

– Please pay attention

to alladvice- and warning stickers placed on the engine and keep them in legi-

ble condition.In case a labelhas com e offoris no longer clearly legible,itmustbe replaced imme-

diately. To this effect,please contact the H ATZ service station in your area.

– Note thatany unauthorized m odification to the engine absolves its manufacturer from liability for

the consequences.

Regular servicing in accordance with the details provided in this instruction book is essentialto

keep

the engine operating reliably.

In case ofdoubt,alw ays consultyour nearestH ATZ service station before starting the engine.

2. D escription ofthe engine

Fig.1

1Fuelline (feed pum p –

fuel-injection pum p)

2Airdeflector

3Oildipstick

4Fuelreturn line

5Injector

6Lifting eyebolt

7Starter motor

8Airguide

9Airintake pipe

10 Type plate

11 G low plug

(additionalequipm ent)

12 O ilbath aircleaner

13 O il

pressure sw itch

14 R ainproofcap

15 O ilfiller cap

16 Fuelpressure pipe

17 Cylinder head cover

18 Engine oilline

19 Exhaustmanifold

20 Fuelinjection pum p

21 Stop lever

22 S peed controllever

23 Fuelfeed pum p

24 Engine oilfilter

25 O ildrain plug

26 G uard

27 Airguide housing

28 Separ

able connector

29 Voltage regulator

30 Engine m ount

31 Crankshaft,pow er-take-off

32 Fuelline

(fuelfilter -feed pum p

33 Fuelfilter

3. G eneralrem arks

3.1. Technicaldata

Type 2 G 40 /2G 40H

Design Air-cooled four-stroke dieselengine

Com bustion system D irectinjection

Num berofcylinders2

Bore/stroke m m 92 /75

Displacem ent cm ³ 997

Engine oilcontent 2.5 excl.sum p

incl.filter renew al l.approx. 3.0 incl.sum p

Difference betw een

„m ax“ and „m in“ levelsl.approx. 0.8

Engine oilpressuremin. 1 bar at 900 r.p.m.engine speed

Engine oilconsum ption

(after running-in period) approx. 1% offuelconsum ption at fullload

Direction ofrotation,

pow er take-offend anti-clockw ise

Valve clearances at 10 -30 °C

Inlet/exhaust m m 0.10

Max.permissible perm.inclination Exhaust Flyw heel

Angle ofinclination in °low high low high

withoutoilsum p 30

with oilsum p 30

Weight(incl.fueltank,air-cleaner,kg

exhaustsilencer and electric starter)approx. 106

Battery capacitymin /m ax 12 V -45 /88 Ah • 24 V -36 /55 Ah

These values are intended as an approximate guide.The max.marking on the dipstick is the

determining factor,Fig.6.

Exceeding these limits causes engine breakdow n.

3.2. Transport

The lifting eyeboltprovided as stand-

ard equipm entis intended forsafe

m ovem entofthe engine.

Itis notintended for lifting com plete machin-

ery to which the engine is attached,and this is

strictly forbidden.

3.3. Instructions for installation

Ifyou have an engine which is notyet installed

in a machine and stillhas to be installed,make

sure thatthe Assem bly Instructions forHATZ

DieselEngines are com plied with prior to instal-

lation.These Assem bly Instructions contain

im-

portant information aboutsafe assem bly ofthe

engine and are available from your the H ATZ

service center in your area.

Pending com plete installation,the engine

mustnotbe started !

Moreover,wew ould like to pointoutthatin this

case,com m issioning ofthe machine is also pro-

hibited untilithas been verified thatthe machine

into which this engine is to be incorporated

com plies with allthe safety precautions and reg-

ulations provided by law .

Refer also to

the Declaration for Incorporation

at the end ofthese Operating Instructions.

The permitted loads and elem ents on

the speed adjusting leverand the stop

lever should be observed as an exess can lead

to dam age to the contacts and inner governor

parts.

3.4. Load on engine

Operating the engine for a lengthy period off-

load orat very low loads can affect its running

quality.

Wetherefore recom m end a minimum engine

load of15 %.Ifoperated atsuch low loads,itis

bestto operate the engine at a

significantly high-

er load fora shortperiod before sw itching itoff.

3.5. Type plate

The type plate is placed on the airguide (Fig.1,

pos.10)and includes the follow ing engine infor-

mation:

➀engine type

➁code (only forspecialequipm ent)

➂engine num ber

➃max.engine speed

For any offer as wellas spare parts orders itis

necessary to mention these data (also see spare

parts list,page 1).

➀➁

➂

➃

4. O peration

4.1. Before initialstart-up

Engines are normally delivered withoutfueland

oil.

4.1.1. Engine oil

Oilquality

Qualified are alltradem ark oils which fulfilat

least one ofthe follow ing specifications:

ACEA – B2 /E2 or more significant

API– CD /CE /CF /CF-4 /CG-4ormore

significant.

Ifengine oil

ofa poorer quality is used,reduce

oilchange intervals to 150 hours ofoperation.

Oilviscosity

Please select the recom m ended viscosity de-

pending on the am bient tem perature at which

the engine is operated.

Inappropriate engine oilmayshorten the

engine’s service life significantly.

-40

-30

-20

-10

10 4

-4

-22

-40

OIL: SAE...

°C°F

5W/30

5W/40

10 W / 4 0

10 W / 3 0

15 W /40

122

10 W

Whenadding oilor checking the level,the en-

gine mustbe in a horizo n talposition.

– Rem ove oilfiller screw „1 “ and dipstick „2 “.

– Add engine oilup to the max.mark on the

dipstick.

Lubricating oilcapacity:see Chapter 3.1.

– Insertthe oilfiller screw and tighten it(hand-

tightonly).

Attention !

Ifthe engine is operated while the oillevelis

below the min. m ark or above the max.mark,

itcan cause dam age to the engine.

4.1.2. O ilbath aircleaner

Ifa cyclone-type dusttrap is fitted,makesure

thatthe dustoutlet is pointing in the correct

direction.

– Fillthe oiltank up to mark „1 “ with engine oil.

– Attach oiltank „2 “, making sure thatsealing

ring „3 “ is correctly seated and clips „4 “ are

fastened securely.

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