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Summary of Contents for Hatz 2W35
- Page 1 INSTRUCTION BOOK 2W35 3W35 4W35 4W35 T 433 916 01-USA-EPA IV-CARB 12.07-0.03 Printed in Germany...
- Page 2 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.
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Page 4: Table Of Contents
Contents Page Page Important safety notes 5.3. Maintenance every 250 when operating the engine operating hours 5.3.1. Change engine oil Description of the engine 5.3.2. Check water trap 5.3.3. Clean the radiator fins General notes 3.1. Technical data 5.3.4. Check screw connections 5.3.5. -
Page 5: Important Safety Notes When Operating The Engine
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. - Page 6 – 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.
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Page 7: Description Of The Engine
Description of the engine 2 W 35 • 3 W 35 • 4 W 35 Operator’s side 1 Speed adjustment lever 10 Engine oil filter 2 Type plate 11 Water drain plug on fuel filter 3 Coolant pump 12 Oil pressure switch 4 Oil dipstick 13 Fuel filter with water trap 5 Oil filler cap... - Page 8 Description of the engine 2 W 35 • 3 W 35 • 4 W 35 Exhaust side 1 Fuel feed pump 10 Fan (optional equipment) 2 Fuel return line 11 Radiator (optional equipment) 3 Stop lever (optional equipment) 12 Coolant supply to engine 4 Exhaust silencer 13 Coolant return to radiator and thermostat 5 Exhaust gas outlet...
- Page 9 Description of the engine 4 W 35 T (turbocharged engine) Operator’s side 1 Speed adjustment lever 10 Oil drain plug (operator’s side) 2 Type plate 11 Oil filler cap 3 Coolant pump 12 Engine oil filter 4 Oil dipstick 13 Water drain plug on fuel filter 5 Fan (optional equipment) 14 Oil pressure switch 6 Hydraulic pump drive (optional equipment)
- Page 10 Description of the engine 4 W 35 T (turbocharged engine) Exhaust side 1 Fuel feed pump 9 Voltage regulator 2 Fuel return line 10 Coolant supply to engine 3 Stop lever or stop solenoid 11 Coolant return to radiator and thermostat (optional equipment) 12 Temperature switch 4 Turbocharger...
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Page 11: General Notes
0.5 % of fuel consumption at full load Lubricating oil pressure (oil temperature 100 °C) approx. 3.5 bars at 3000 r.p.m. Capacity of coolant with HATZ standard radiator l. approx. Direction of rotation, looking at the flywheel counterclockwise Max. admissible tilt angle in operation (with lub-oil level at max. -
Page 12: Transport
You can obtain a copy of this manual from your nearest HATZ service station. Watch out for the eyebolt securing points. -
Page 13: Epa / Carb - Type Plates
3.5. EPA/CARB-type plates and For any offer as well as spare parts orders it is necessary to mention the following data (also fuel label see spare parts list, page 1): There are two EPA/CARB- type plates applied for ➁ engine type / spec. the identification of the engine. -
Page 14: Emission-Related Installation Instructions
Fuel label Operation 4.1. Before initial start-up The engines are normally delivered to the cus- tomers without fuel, oil and coolant filling ! LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Important ! When replenishing liquids, it is essential that any danger of confusion be excluded, as mixing up liquids may cause serious damage to the engine. -
Page 15: Coolant
Attention ! If the engine is operated while the oil level is be- low the min. mark, it will be damaged. 4.1.2. Coolant The following radiator protection fluids have been authorized by HATZ: Manufacturer Product description BASF Glysantin ®... - Page 16 Should you have any questions about the ideal mixing ratio at your place of engine operation, please do not hesitate to contact your HATZ service station.
- Page 17 Note: – After the engine has warmed up, check coolant As the concentration of the corrosion- and anti- level again. When the engine is at a standstill freeze protection fluid deteriorates long-term, it and has cooled down, the coolant level must must be checked yearly using a commercial an- be visible between the tank’s MIN and MAX tifreeze tester.
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Page 18: Fuel
4.1.3. Fuel Low temperature resistance At low temperatures, the viscosity of Diesel fuel Only refuel when engine is stopped. increases. This may result in clogging of the fuel Never refuel close to open flames or system. Thus, winter fuel must be used at out- flammable sparks, don’t smoke. -
Page 19: Starting The Engine
Fuel tank LOW – Start the engine as described in Chapter 4.2. Models with electrical supply pump If the fuel tank is located at an even lower level, a manual fuel pump or an electrical supply pump – With this model, first turn the starter key to must be used for bleeding. -
Page 20: Electric Starter
4.2.1. Preparations for starting 4.2.2. Electric starter – If possible, disengage the engine from any To save the starter and the battery, do not driven equipment. The auxiliary equipment actuate the starter continuously for more than should always be placed in neutral. 15 to 20 seconds at a time. - Page 21 – The engine temperature indicator 4 goes on as Automatic electrical shutdown system soon as the coolant becomes inadmissibly hot. (optional equipment) Stop the engine immediately and trace and This is characterized by a brief flashing of all eliminate the cause of the problem, Chap. 6. pilot lamps once the starter key has been turned –...
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Page 22: Stopping The Engine
4.3. Stopping the engine When the engine is not running any longer, release stop lever. The stop lever is returned If operation of the engine is interrupted automatically to its operating position START for any reason, or at the end of the via a spring (Fig. -
Page 23: Maintenance
5. Maintenance Only carry out maintenance work with the engine switched off. For handling and disposal of used oil, coolant, filters and cleaning agents, comply with the statutory regulations. Unauthorized access to the starter key must be prevented. Disconnect the negative battery terminal. When maintenance work has been completed, check that all tools have been removed from the engine and all protective guards fitted again. - Page 24 The maintenance scheme shown above is sup- For new or reconditioned engines, the following plied with every engine. This stick-on label must always be carried out after first 50 operat- should be provided in an easily visible position ing hours: on the engine.
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Page 25: Maintenance Every
8 - 15 5.2.2. Check combustion air intake area 5.2. Maintenance every operating hours Severe contamination is a sign that there are large amounts of dust in the atmosphere and 5.2.1. Check engine oil level the air cleaner maintenance intervals should be When checking the oil level, the engine should reduced, Chapter. -
Page 26: Check Air Cleaner Maintenance Indicator
5.2.4. Check radiator fins for contamination Serious contamination means that the mainte- nance intervals must be shorted appropriately due to excessive amounts of dust. – In case of models with cyclone precleaner, check the dust ejector valve for free passage; if necessary, remove deposited dust by com- pressing the valve. -
Page 27: Maintenance Every
– In this case, check the cooling system for leak- age and eliminate the reason immediately – in case of doubt, consult the HATZ Service. In case of leaky hose connections, re-tighten the hose clamps. Note:... -
Page 28: Clean The Radiator Fins
5.3.3. Clean the radiator fins For cleaning, the engine must be at a standstill and have cooled down. Important ! The delicate radiator fins must never be cleaned using tools, such as a screw-driver or a spatula. Deformed radiator fins or radiator leakage may reduce the radiator performance. -
Page 29: Check Screw Connections
5.3.4. Check screw connections 5.3.5. Check the Vee belt (optional equipment) – Check the tightness of all threaded connec- tions and take up slack if necessary, provided – Check the Vee belt over its entire circumference that these can be reached during maintenance for cracks or damage;... -
Page 30: Maintenance Every
Replace the Vee belt 5.4. Maintenance every operating hours 5.4.1. Replace primary fuel filter Note: Primary fuel filter maintenance intervals depend on the purity of the fuel used in the engine and should be reduced to 250 hours if necessary. Do not smoke and never bring a naked flame near the fuel system when work- ing on it. -
Page 31: Replace The Engine Oil Filter
Important: When installing a new filter, note the arrow indi- cating the correct flow direction (depends on whether the tank is mounted HIGH or LOW. The filter’s installed position (direction of flow) should be as vertical as possible. – Open the fuel supply line. –... -
Page 32: Air Cleaner Maintenance
– Turn-in replaceable-cartridge filter and tighten it by hand. – Assemble the air filter cartridges and the cover for the air cleaner, Chapter 5.4.3. – Replenish lubricant of the appropriate specifi- cation and viscosity until the level reaches the MAX mark of the dipstick (Chapter 4.1.1). –... - Page 33 – Tilt air cleaner cover forwards (arrow 1), then – Check seal 1 and rubber pad 2 for damage, de- lift it and remove it (arrow 2). formation and cracks; if necessary, replace. – The filter cartridge must either be replaced or - depending on the degree of contamination - cleaned or checked: Cleaning the filter cartridge...
- Page 34 Moist or oily contamination – Renew the filter cartridge. Checking the filter cartridge – Check filter cartridge’s gasket surface 1 for damage, Fig. 50. – Check the filter cartridge for cracks or any other type of damage to the paper filter by holding it inclined towards the light or by shining a light source through it.
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Page 35: Maintenance Every 1000 Operating Hours
1000 5.5. Maintenance every operating hours 5.5.1. Renew the fuel filter Note: Fuel filter maintenance intervals depend on the purity of the fuel used; reduce them to 500 hours of operation if necessary. Do not smoke and never bring a naked flame near the fuel system when work- ing on it. -
Page 36: Maintenance: Every 4 Years
5.6. Maintenance: every 2 – 4 years 5.6.1. Replacement of coolant Note: Depending on which radiator protection fluid is used, a replacement interval of 2 or 4 years is envisaged. The various products are charac- terized by their identification colour. For further explanations, refer to Chapter 4.1.2. - Page 37 – Unscrew the drain plug 1 from the engine and drain coolant. – Subsequently unscrew the drain plug 1 from the radiator and drain the coolant as well. – Turn-in drain plugs 1 with new packing ring 2 and tighten them (Fig. 59 and 60). –...
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Page 38: Malfunctions - Causes - Remedies
Malfunctions – Causes – Remedies Malfunction Possible causes Remedy Chap. 6.1. Speed control lever is in stop or Engine will not start idle position. Set lever or start is Stop lever in stop position. to „START“-position 4.2.1. delayed, although it can be turned over No fuel reaching injection pump. - Page 39 Locate the responsible monitoring electrical shutdown monitoring elements has initiated element and clear the fault, or con- installed a stop signal. tact a HATZ service station. (optional equipment) (See also Chapter 6.4.). 6.3. Fault in the electrical system: Starter motor does...
- Page 40 - Primary fuel filter or fuel filter Change fuel filter. 5.4.1. operation. clogged. 5.5.1. Mechanical faults Contact a HATZ service station. With automatic One of the automatic shutdown’s Locate the responsible monitoring electrical shutdown monitoring elements has initiated element and clear the fault, or con- 4.2.2.
- Page 41 Clean the radiator fins. 5.3.3. - Loss of coolant. Check cooling system for leakage and eliminate cause - in case of doubt, contact the HATZ Service station. Subsequently, replenish coolant. 4.1.2. - Vee belt broken or slack (only in case of models with belt-driven fan).
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Page 42: Work On The Electrical System
HATZ assumes no liability for electrical systems In case of emergency call a doctor. which have not been carried out acc. to HATZ Do not place any tools on top of the battery. circuit diagrams. Always disconnect the negative (–) terminal of the battery before working on the electrical system. -
Page 44: Supplemental Information To The Owner's Manual For 2008 And Later Epa Certified Nonroad Compression Ignition Engines
SUPPLEMENTAL INFORMATION TO THE OWNER'S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS. - Page 45 ENGINE PARTS AND / OR EQUIPMENT RELATED TO EPA EXHAUST EMISSION REGULATIONS. Parts which are mandatory for engine operation. The following parts as manufactured according to HATZ specifications are mandatory for engine operation which meets EPA exhaust emission regulations. • Air cleaner housing •...
- Page 46 • PCV ( 'positive crankcase ventilation' ) connection assembly • Exhaust manifold • Emission Control Information Labels Only parts manufactured by Hatz and which have passed the Hatz Quality Assurance Program are assured of meeting EPA exhaust emission regulations. UNUSUAL OPERATING CONDITIONS.
- Page 47 Therefore, the maintenance work has to be carried out by a qualified workshop. Hatz authorised workshops, for example, are qualified workshops. Hatz Diesel of America will give you respective addresses, if required. EMISSION CONTROL SYSTEM AND ADJUSTMENTS. The emission control system for this engine is EM (Engine Modification).
- Page 48 EPA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS. Motorenfabrik Hatz GmbH & Co. KG warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.
- Page 49 • As the engine owner, you should be aware, however, that Motorenfabrik Hatz may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
- Page 50 PARTS WITH SUPPLEMENTAL LIMITED WARRANTY. The following limited warranty is supplemental to the standard HATZ DIESEL LIMITED ENGINE WARRANTY and covers 2008 and later EPA certified engines and applies to the following exhaust emission-related components: • Air cleaner housing • Cold air duct •...
- Page 51 Hatz Diesel of America, Inc. hereinafter referred to as “HATZ” warrants each of the above-listed parts when installed in a new engine sold by Hatz to be free from defects in material and workmanship under normal use and service, only under the named warranty...
- Page 52 EMISSION-RELATED INSTALLATION INSTRUCTIONS “Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40CFR1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.” “If you install the engine in a way that makes the engine's emission control information labels hard to read during normal engine maintenance, you must place duplicate labels on the equipment.”...
- Page 53 Following are the instructions to properly install the exhaust system and related components consistent with the EPA emission regulation requirements. 2W35 · 3W35 · 4W35 (T) Electrical starter The electrical starter is fitted in connection with washers, hex.-nuts and Allen screws.
- Page 54 2W35 · 3W35 · 4W35 (T) Exhaust-silencers The exhaust silencer is fitted in connection with washers, hex.-nuts, metal bellows and a protection plate. Dismantling: • Remove in numerical sequence 1...7. Assembly: • Assemble in reverse sequence.
- Page 55 SAMPLING OF EXHAUST EMISSIONS After the engine is installed in the equipment and placed in service, the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample with ambient air as follows: Version 1 Specification 1: Adding a 20-centimeter linear extension to the exhaust pipe...
- Page 56 Version 2 Specification 2: Adding a 20-centimeter bended extension to the exhaust pipe Version 1 Version 2 Clamp Engine type Ø d (mm) HATZ-Ident. Nr. HATZ-Ident. Nr. HATZ-Ident. Nr. 2W35 830 857 000 830 858 00 037 409 00 3W35...
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Page 58: Supplemental Information To
SUPPLEMENTAL INFORMATION TO THE OWNER´S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS. - Page 59 ENGINE PARTS AND / OR EQUIPMENT RELATED TO CARB EXHAUST EMISSION REGULATIONS. Parts which are mandatory for engine operation. The following parts as manufactured according to HATZ specifications are mandatory for engine operation which meets CARB exhaust emission regulations. • Air cleaner housing •...
- Page 60 • Exhaust manifold • Emission Control Information Labels Only parts manufactured by Hatz and which have passed the Hatz Quality Assurance Program are assured of meeting CARB exhaust emission regulations. UNUSUAL OPERATING CONDITIONS. The engine must not be operated at a load factor less than 25 % for an extended period as such operation will cause the fuel injector to foul.
- Page 61 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT. YOUR WARRANTY RIGHTS AND OBLIGATIONS. The California Air Resources Board and Motorenfabrik Hatz GmbH & Co. KG are pleased to explain the emission control system warranty on your 2008 and later engine. In California, new heavy-duty off-road engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
- Page 62 • As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Motorenfabrik Hatz GmbH & Co. KG recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Motorenfabrik Hatz GmbH & Co.
- Page 63 CALIFORNIA CERTIFIED HEAVY-DUTY OFF-ROAD ENGINES. PARTS WITH SUPPLEMENTAL LIMITED WARRANTY. The following limited warranty is supplemental to the standard HATZ DIESEL LIMITED ENGINE WARRANTY and covers 2008 and later California certified Heavy-Duty off- road engines and applies to the following exhaust emission-related components: •...
- Page 64 Hatz Diesel of America, Inc. hereinafter referred to as "HATZ" warrants each of the above-listed parts when installed in a new engine sold by Hatz to be free from defects in material and workmanship under normal use and service, for a period of twenty-four (24)
- Page 65 EMISSION-RELATED INSTALLATION INSTRUCTIONS “Failing to follow these instructions when installing a certified engine in a piece of nonroad equipment violates federal law (40CFR1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.” “If you install the engine in a way that makes the engine's emission control information labels hard to read during normal engine maintenance, you must place duplicate labels on the equipment.”...
- Page 66 Following are the instructions to properly install the exhaust system and related components consistent with the EPA emission regulation requirements. 2W35 · 3W35 · 4W35 (T) Electrical starter The electrical starter is fitted in connection with washers, hex.-nuts and Allen screws.
- Page 67 2W35 · 3W35 · 4W35 (T) Exhaust-silencers The exhaust silencer is fitted in connection with washers, hex.-nuts, metal bellows and a protection plate. Dismantling: • Remove in numerical sequence 1...7. Assembly: • Assemble in reverse sequence.
- Page 68 SAMPLING OF EXHAUST EMISSIONS After the engine is installed in the equipment and placed in service, the sampling of exhaust emissions can be performed in a way that prevents diluting the exhaust sample with ambient air as follows: Version 1 Specification 1: Adding a 20-centimeter linear extension to the exhaust pipe...
- Page 69 Version 2 Specification 2: Adding a 20-centimeter bended extension to the exhaust pipe Version 1 Version 2 Clamp Engine type Ø d (mm) HATZ-Ident. Nr. HATZ-Ident. Nr. HATZ-Ident. Nr. 2W35 830 857 000 830 858 00 037 409 00 3W35...
- Page 70 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
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