Hatz Diesel Silent Pack 2-4L41C Manual
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Hatz Diesel Silent Pack 2-4L41C Manual

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CREATING POWER SOLUTIONS.
2-4L41C | 2-4M41 | 4L42C | 4M42
MANUAL
for diesel engine
Hatz Diesel
www.hatz-diesel.com

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Summary of Contents for Hatz Diesel Silent Pack 2-4L41C

  • Page 1 CREATING POWER SOLUTIONS. 2-4L41C | 2-4M41 | 4L42C | 4M42 MANUAL for diesel engine Hatz Diesel www.hatz-diesel.com...

  • Page 3: Table Of Contents

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Table of contents Table of contents Notices .........................  5 General information ....................  6 Safety ........................ 7 General information ...................... 7 3.1.1 Intended use and foreseeable misuse.................  7 3.1.2 Machine user or machine manufacturer obligations ............ 8 3.1.3 Representation of safety notes ....................
  • Page 4 Table of contents 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Checking the water separator....................  57 Check the oil level...................... 58 Maintenance ......................  60 General maintenance instructions .................. 60 Maintenance work...................... 61 8.2.1 Maintenance notice label .................... 61 8.2.2 Maintenance plan ...................... 63 8.2.3 Checking the intake area of the combustion air..............

  • Page 5: Notices

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Notices Notices Contact data © 2020 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, Ruh- storf.

  • Page 6: General Information

    Machine This manual describes the following machine. Machine name HATZ diesel engine Type number 2-4L41C  2-4M41  2-4M41Z  4M42  4L42C Customer service Have service work performed by qualified technicians only. We recommend that you work with one of the over 500 HATZ service stations.

  • Page 7: Safety

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety Safety General information Introduction This chapter contains the information you need to work safely with this ma- chine. To prevent accidents and damage to the machine, it is imperative that these safety instructions be followed. Read this chapter carefully before beginning work.

  • Page 8: 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 be- fore installing the engine. These assembly instructions contain important in- formation on how to safely install the engine and are available at your near- est HATZ service station.

  • Page 9: Representation Of Safety Notes

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety 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 accessi- ble 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 tech-...

  • Page 10: Meaning Of Safety Symbols

    Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Signal words Signal words identify the magnitude of the risk and the seriousness of the possible injuries: Danger symbol/ Meaning signal word This signal word is used to indicate imminently DANGER dangerous situations which, if not avoided, will lead to serious injury or death.
  • Page 11 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety 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. Additional information that is useful to the reader.

  • Page 12: Safety Notes

    Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety notes 3.2.1 Operational safety Introduction This chapter contains all of the important safety instructions for personal pro- tection and for safe and reliable operation. Additional, task-related safety in- structions can be found at the beginning of each chapter. DANGER Danger to life, danger of injury or danger of property dam- age due to failure to comply with this manual and the safety...
  • Page 13 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety Personal protective Pictogram Function equipment Safety shoes Safety shoes offer protection against: ▪ Slipping ▪ Falling objects Hearing protection Hearing protection offers protec- tion against ear injuries due to excessive and constant noise. Safety gloves Safety gloves protect the hands against injury, e.g.
  • Page 14 Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 15: Machine-Specific Safety Instructions For Operation

    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 be- fore installing the engine. These assembly instructions contain important information on safe installa- tion.

  • Page 16: Machine-Specific Safety Instructions For Maintenance Work

    Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.
  • Page 17 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety ▪ 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.

  • Page 18: Electrical Equipment

    Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. 3.2.4 Electrical equipment Safety notes DANGER Danger to life, danger of injury or danger of property dam- age due to incorrect use of batteries.
  • Page 19 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Safety 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.

  • Page 20: Labels

    Safety 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Labels Warning labels and information signs on the engine Label Meaning Maintenance instructions (see the chapter 8.1 General maintenance in- structions, page 60) CAUTION! Damage from inadequate engine cooling. ▪ Only run the engine when all cov- ers are installed.

  • Page 21: Technical Data

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Technical data Technical data Engine information and filling quantities Type 2L41C 3L41C 4L41C / 4L42C 2M41. 3M41. 4M41. / 4M42 Type Air cooled, four stroke diesel engine Combustion system Direct injection Number of cylinders Bore/Stroke 102 / 105 102 / 105 102 / 105 Displacement...
  • Page 22 Technical data 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Engine oil capacities and dipstick equipment Type Oil sump Engine oil capacity Mark on the dip- liters stick 2L41C With 2M41Z Without 2M41 With Without 3L41C With 10.5 3M41Z Without 3M41 With 11.0 Without 4L41C With 13.0...

  • Page 23: Engine Type Plate

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Technical data Engine type plate EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ GMBH KG ¬ D-94099 RUHSTORF www.hatz-diesel.com Model: Build: S/N: Power: Displ: Eng.Fam: Emission Control System: Power Category: ULTRA LOW SULFUR DIESEL FUEL ONLY. THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR MY2018 NONROAD DIESEL ENGINES.

  • Page 24: Physical Operating Conditions

    Technical data 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Physical operating conditions Engine adjustment The engine is normally adjusted to operate within the standard reference conditions stipulated in ISO 3046-1: Parameter Unit Value Intake air temperature °C Relative humidity Air pressure (at approx. 100 meters above sea level) NOTICE If the machine is operated at high altitudes and high tempera-...

  • Page 25: Fuel

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Technical data Oil viscosity OIL: SAE... °F °C 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.
  • Page 26 Technical data 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 de- posits result in malfunctions due to clogged fuel filters and dam- age to the injection system.

  • Page 27: Engine Design

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Engine design Engine design Engine 2-4L41C Encapsulated model "Silent Pack" Pos. Designation Access cap for fuel feed pump Oil filling opening and dipstick Type plate Speed control lever Oil filter Exhaust silencer (encapsulated) Cover for air guide housing (access to cooling fan belt) Engine brackets Oil drain screw Cover plate on operating side...
  • Page 28 Engine design 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Pos. Designation Air intake duct for capsule Intake opening for combustion air and cooling air Fuel feed line with fuel prefilter Fuel return line Cover plate on air outlet side Central connector for electrical equipment Battery connections Powerbox Electrical maintenance switch for air filter...
  • Page 29 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Engine design Pos. Designation Exhaust silencer (encapsulated) Cover for air guide housing (access to cooling fan belt) Engine brackets Oil drain screw Cover plate on operating side Side panel Air outlet duct for cooling air Capsule hood Retractable lifting eye, max.
  • Page 30 Engine design 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Engine 2-4M41, 2-4M41Z Standard model Pos. Designation Oil filling opening and dipstick Side trim panel Intake opening for combustion air Cooling fan belt Cooling fan with installed three phase alternator 1/2-inch square socket for turning the engine Oil drain screw Speed control lever Oil filter...
  • Page 31 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Engine design Pos. Designation Fuel return line Fuel feed line with fuel prefilter Type plate Silencer Central connector for electrical equipment Battery connections Powerbox Electrical maintenance switch for air filter Engine 4M42 Standard model Pos. Designation Oil filling opening and dipstick Side trim panel Intake opening for combustion air...
  • Page 32 Engine design 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Pos. Designation Oil drain screw Speed control lever Oil filter Oil drain screw (on oil sump) Cooling air guide for oil cooler Fuel filter Cylinder head cover Air filter housing cover Lifting eye, max. load 5000 N Fuel return line Fuel feed line with fuel prefilter and manual fuel pump Type plate...

  • Page 33: Transport, Assembly And Commissioning

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Transport, assembly and commissioning Transport, assembly and commissioning 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.
  • Page 34 Transport, assembly and commissioning 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Overview – lifting eye Capsule hood (2-4L41C, 4L42C) Lifting eye, recessable (2-4L41C, 4L42C) Lifting eye (2-4M41, 2-4M41Z, 4M42) Fixing screws for lifting eye Procedure Step Activity In encapsulated version, remove hood (1). Ensure that the fixing screws (4) are tight. Then lift the engine. Transport conditions ▪...

  • Page 35: Installation Notes

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Transport, assembly and commissioning 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 commer- cial purposes. The machine manufacturer must follow the applicable regulations regarding machine safety –...

  • Page 36: Preparations For Commissioning

    Transport, assembly and commissioning 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.
  • Page 37 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Transport, assembly and commissioning Overview Dipstick Code letter on the dipstick Procedure Step Activity Pull out the dipstick (1) and clean it. Fill engine oil. For the specification and viscosity, see chapter 4.4 Engine oil, page 24. The code letter on the dipstick (2) indicates whether the engine is equipped with an oil sump or not.For the filling quantity, see chapter 4.1 Engine information and filling quantities, page 21.

  • Page 38: Operation And Use

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Safety notes NOTICE Comply with the safety chapter! Follow the basic safety instructions in chapter 3 Safety, page 7. WARNING Danger of injury from damage and defects on the machine. ▪...

  • Page 39: Performing Tests

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Performing tests Before starting Before starting the engine, several tests need to be performed to ensure the machine is working properly. Procedure Step Test The machine is standing securely and on a level surface. The installation location is adequately ventilated.

  • Page 40: Pumping Fuel With The Manual Fuel Pump

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Overview Manual lever (fuel feed pump) Return line Procedure Step Activity Fill with fuel if necessary. Remove the access cap for the fuel feed pump. Actuate the manual lever (1) on the fuel feed pump until the fuel audibly flows back into the fuel tank through the return line (2).
  • Page 41 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Model with manual fuel pump Only for 4L42C and 4M42 Bleed screw Filter Rubber ball Procedure Step Activity If there is air in the fuel system: Fill with fuel if necessary. Place a suitable container under the filter (2) to collect emerging fuel.

  • Page 42: Setting The Speed Control

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Setting the speed control Overview ½ Procedure Step Activity Depending on the situation, place the speed control lever in either the "1/2" or "Start" position. NOTICE A lower speed setting will cause less exhaust smoke when start- ing.
  • Page 43 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use CAUTION Danger of injury from defective crankhandle. A damaged or broken handle bar can cause injuries. A worn cranking shaft can slip out of the starting mechanism when start- ing and also cause injuries. ▪...
  • Page 44 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Turning over the engine: Safety note CAUTION Danger of engine damage from decompression while the engine is running. ▪ Do not operate the decompression lever while the engine is running. Overview Decompression lever Attach the crank handle Position of operator 0 - 3...
  • Page 45 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Preparation Step Activity Carry out start preparations (see the chapter 7.3 Start prepara- tion, page 39). Move the speed control lever into position "Start" (see the chap- ter Setting the speed control). Move all decompression levers to position "1". ▪...

  • Page 46: Starting The Engine

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Starting the engine Safety note CAUTION Danger of injury from recoiling of the engine. ▪ Use a crankhandle with a recoil damper. ▪ Hold the handle bar so that it cannot twist and quickly turn the crank so that continuous traction between the engine and crank is ensured.
  • Page 47 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Crank handle Attach the crank handle Handle bar Crank arm Drive dog Guide sleeve Preparation The decompression lever must be set depending on the number of cylinders of the engines 2-4M41.. HATZ Manual...
  • Page 48 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity Setting the decompression lever: ▪ Two cylinder engine 2M41. Turn the lever to position "2". ▪ Three cylinder engine 3M41. Turn the levers of the 1st and 3rd cylinders to position "2". Turn the lever of the 2nd cylinder to position "3".

  • Page 49: Starting The Engine With A Starter

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Step Activity As soon as the engine starts, pull the crank handle out of the guide sleeve (4). 7.5.2 Starting the engine with a starter Overview — HATZ instrument boxes Protective cap Starting key Pre-glow display (option) Air filter maintenance display Engine temperature display (option)
  • Page 50 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Explanation of symbols Symbol Meaning Operating indicator Lights up during operation when there is no engine fault. Charge control Fault in the alternator or alternator charging circuit. The battery is no longer charged. Eliminate the fault immediately. Oil pressure display Engine oil pressure too low.
  • Page 51 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use NOTICE The starter protection module prevents the starter from engag- ing while the engine is running and becoming damaged. ▪ The starter protection module is required when the user cannot detect at the ignition lock if the engine is still running or is already at a standstill.
  • Page 52 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 NOTICE ▪ If the engine stops again immediately after starting, or stops independently during operation, this is an indication that a monitoring element of the automatic shutoff has activated. ▪ Remedy the fault before making further starting attempts (see chapter 9.1 Trouble shooting, page 98).

  • Page 53: Switching Off The Engine

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Flashing codes The indicator (5) only flashes during operation if a problem arises in connec- tion with the exhaust gas return system. This includes a dirty air filter. This can be identified by the following flash code of the indicator (5): ▪...

  • Page 54: Switching Off The Engine (Mechanical)

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Methods of switching off the engine The engine can be switched off in different ways depending on how it is equipped: ▪ Speed control lever (mechanical) ▪ Starting key (electrical) 7.6.1 Switching off the engine (mechanical) Overview Procedure Step...

  • Page 55: Switching Off The Engine (Electrical)

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 7.6.2 Switching off the engine (electrical) Overview — HATZ instrument boxes Protective cap Starting key Ignition lock Operation Procedure Step Activity Turn the starting key (2) to position "0". The engine switches off. All indicator lamps go out.

  • Page 56: Refueling

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Refueling This diesel engine is intended for installation in a machine or for assembly with other machines to form a machine and does not have its own fuel tank. Follow the instructions from the manufacturer and comply with the following safety information.

  • Page 57: Checking The Water Separator

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use Checking the water separator Only for engines 4L42C and 4M42 Safety notes CAUTION Danger of environmental damage from spilled fuel. When water is drained from the water separator, a small amount of fuel is drained as well. ▪...

  • Page 58: Check The Oil Level

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity Open the drain screw (1) and drain the water into the container. If not enough liquid escapes, undo additional screw (2). As soon as fuel escapes, close the drain plug (1) and screw (2). NOTE: First water escapes then fuel.
  • Page 59 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use CAUTION Danger of later engine damage. ▪ Operating the engine with an oil level below the min. mark or above the max. mark can lead to engine damage. ▪ When checking the oil level, the engine must be horizontal and have been switched off for a few minutes.

  • Page 60: Maintenance

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance General maintenance instructions Safety notes WARNING Danger of injury from failure to follow the operating instruc- tions and from performing unauthorized tasks on the ma- chine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is avail- able.

  • Page 61: Maintenance Work

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance ▪ Before starting, ensure that no persons are located in the danger zone of the engine or machine. Performance of maintenance work The entire machine is designed to be maintenance friendly. Parts that re- quire maintenance are easily accessible. ▪...
  • Page 62 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 2M41. Without oil sump 0,1 mm 0.004" 2M31 2M40 2M41 = 1h 500h 250h 2M41. With oil sump; 3-4M41. and 4M42 in general 0,1 mm 0.004" .M31/.M40 .M41/.M42 = 1h 500h 250h Manual HATZ...

  • Page 63: Maintenance Plan

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 2-4L41C; 4L42C 8.2.2 Maintenance plan In new and generally overhauled engines, after 25 operating hours: ▪ Change the engine oil ▪ Check the tappet clearance and adjust if necessary ▪ Check the screw connections (do not retighten the screws for attaching the cylinder head) In case of a low number of operating hours, change the engine oil no later than every 12 months, regardless of the actual number of operating hours.

  • Page 64: Checking The Intake Area Of The Combustion Air

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Symbol Maintenance in- Maintenance step/check Chapter terval Every 8–15 oper- Check the oil level. 7.9 Check the oil level, ating hours or ev- page 58 ery day before Check the intake area of the 8.2.3 Checking the in- starting combustion air.
  • Page 65 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Symbol Maintenance in- Maintenance step/check Chapter terval Every 500 operat- Change the fuel prefilter. 8.2.10 Changing the fuel 500h ing hours prefilter, page 78 Maintain the dry air filter. 8.2.11 Maintaining the dry air filter, page 80 Change the filter cartridge.
  • Page 66 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 NOTICE In case of heavy contamination, shorten the maintenance inter- vals accordingly (see chapter 8.2.2 Maintenance plan, page 63). Overview 2-4M41 and 4M42 2-4L41C and 4L42C Intake opening for combustion air Dust outlet opening Cyclone (option) Procedure Step Activity...
  • Page 67 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Electrical air filter maintenance display 2-4L41C and 2-4M41 4L42C and 4M42 Air filter service indicator Mechanical air filter maintenance display Red field HATZ Manual...
  • Page 68 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Procedure Step Activity For the electrical air filter maintenance display: Briefly let the engine run at maximum speed and watch for the indicator (5) to light up for a short period – depending on the version.

  • Page 69: Change The Engine Oil

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance CAUTION Danger of engine damage from overheating. The engine temperature display (option) lights up as soon as the engine becomes impermissibly hot. ▪ Switch off the engine immediately and eliminate the cause. NOTICE In case of heavy contamination, shorten the maintenance inter- vals accordingly (see chapter 8.2.2 Maintenance plan, page 63).
  • Page 70 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Overview Oil drain screw Drain pipe Draining the oil Step Activity Unscrew the oil drain screw (1) and drain the oil entirely. When unscrewing the oil drain screw (1) on engines of type 2-4L41C and 4L42C, ensure that the drain pipe (2) is not loos- ened.

  • Page 71: Checking The Poly V Belt

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Procedure — Adding oil Step Activity Add engine oil to the max. mark on the dipstick (1). ▪ For the specification and viscosity, see chapter 4.4 Engine oil, page 25. ▪ The code letter on the dipstick (2) indicates whether the en- gine is equipped with an oil sump or not (see chapter 4 Technical data, page 21).
  • Page 72 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Overview Belt tensioner Poly v belt Damage on the poly v belt Transverse cracks on the rear Fraying on the edges Transverse cracks in multiple ribs Broken ribs Procedure Step Activity Check the belt tensioner (1) for leaks. If the belt tensioner is oily, contact HATZ service.

  • Page 73: Cleaning The Cooling Fan, Cooling Fins And Oil Cooler

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 8.2.7 Cleaning the cooling fan, cooling fins and oil cooler Safety notes 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 gen- erate an explosive gas/air mixture.
  • Page 74 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 CAUTION Damage from inadequate engine cooling. Only operate the engine when all covers are installed. NOTICE In case of heavy contamination, shorten the maintenance inter- vals accordingly (see chapter 8.2.2 Maintenance plan, page 63). Overview — Preparatory activities Baffle plate Preparation —...
  • Page 75 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Overview — Cleaning Procedure — Cleaning Step Activity Cleaning in case of dry dirt contamination Clean the cooling fan, cylinder head and cylinder with a suit- able brush. Blow out the entire cooling air area with compressed air. Blow out the oil cooler with compressed air only.

  • Page 76: Checking The Screw Connections

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity Determine the cause of the oil contamination and have leaks corrected by the HATZ service station. Mount the capsule and air guide parts again. Let the engine run warm to prevent rust formation. 8.2.8 Checking the screw connections Safety note NOTICE...
  • Page 77 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance CAUTION Danger of injury There is a danger of injury when performing cleaning work at the exhaust screen. ▪ Wear safety gloves. NOTICE Operation of the engine for a lengthy period without a load or with only a small load can result in premature deposits on the screen insert.

  • Page 78: Changing The Fuel Prefilter

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 8.2.10 Changing the fuel prefilter Safety notes DANGER Fire hazard from fuel. Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Never refuel in the vicinity of open flames or sparks that can cause ignition.
  • Page 79 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Overview Fuel lines Fuel prefilter Procedure Step Activity Place a suitable container under the filter to collect emerging fuel. Close the fuel feed line. Pull the fuel lines (1) off of the fuel prefilter (2) on both sides. Dispose of the old filter in accordance with local environmental regulations.

  • Page 80: Maintaining The Dry Air Filter

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity After completion, insert the access cover to the fuel feed pump back in the side wall. 4L42C and 4M42 If you have difficulties starting the engine, bleed the injection system with the aid of the manual fuel pump (see the chapter 7.3.2 Pumping fuel with the manual fuel pump, page 40).
  • Page 81 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Removing the air filter cartridge - engines 2-4L41C and 4L42C Step Activity Remove the capsule hood. Remove adherent dirt in the area of the air filter housing (4). Only loosen the screws (1) to the point where you can lift off the complete air filter housing (4).

  • Page 82: Checking And Cleaning The Air Filter Cartridge

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Filter cartridge Air filter housing Removing the air filter cartridge - engines 2-4M41. and 4M42 Step Activity Release the clamps (1) and remove the cover of the air filter housing (2). Remove adherent dirt in the air filter area. Only loosen the screws (3) to the point where the filter cover (4) can be removed with the filter cartridge (7).
  • Page 83 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Overview — Checking/cleaning the air filter cartridge Sealing surface Step Activity Dry contamination Blow out the filter cartridge with dry compressed air from the in- side to the outside until dust no longer emerges. Check the sealing surfaces (2) of the filter cartridge for damage. Check the filter cartridge for cracks in the filter paper and other damage by holding it against the light at a slant or letting light from a lamp shine through it.

  • Page 84: Check And Set The Tappet Clearance

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Procedure — Mounting the air filter cartridge Step Activity When assembling, mount the parts individually one after the other to make sure they are correctly seated and to ensure leak tightness. After the filter is mounted, unlock the visible red field (1) in the maintenance display by pressing the reset button (2).
  • Page 85 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Preparation — Adjusting the tappet clearance Step Activity On encapsulated engines, remove the hood of the capsule (see chapter 5 Engine design, page 27). Remove the hex nut (2) and remove the cylinder head cover (3). Remove the air guide housing cover (see chapter 5 Engine de- sign, page 27) and belt guard.
  • Page 86 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Setting method for three and four cylinder engines Type Valve no. ... fully Check the valves of opened the ... cylinder 3rd cylinder 3-cylinder 2nd cylinder 1st cylinder 3rd cylinder 4-cylinder 4th cylinder 2nd cylinder 1st cylinder Overview —...

  • Page 87: Changing The Oil Filter

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Step Activity Mount the cylinder head cover again: ▪ Always renew the gaskets. ▪ Use the fixing nuts for the cylinder head cover no more than twice before renewing them. ▪ Tightening torque: 10 Nm. Mount all covers.

  • Page 88: Change The Main Fuel Filter

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Gasket Procedure Step Activity Release the oil filter (1) with a strap wrench (2) and quickly un- screw it or pull it out. ▪ HATZ order no. for strap wrench: 620 307 01. Dispose of the old filter in accordance with local environmental regulations.
  • Page 89 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance CAUTION Danger of injury Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. CAUTION Danger of environmental damage from spilled fuel. When the filter is removed, a small amount of fuel is drained as well.
  • Page 90 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity On encapsulated engines: ▪ Lift off the capsule hood (see the chapter 5 Engine design, page 27). On engines without a capsule: ▪ Remove the side trim panel (see the chapter 5 Engine design, page 27). Place a suitable container under the filter to collect emerging fuel.
  • Page 91 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Overview 4L42C and 4M42 Drain plug Preparation 4L42C and 4M42 Step Activity Close the fuel lines on the filter housing. Place a suitable container under the filter to collect emerging fuel. Release the drain screw (1) and drain the fuel. Overview 4L42C and 4M42 Strap wrench (HATZ order no.: 620 307 01) Gasket...

  • Page 92: Checking That The Air Filter Maintenance Indicator Is Working Properly

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Procedure 4L42 C and 4M42 Step Activity Slide on the strap wrench (1) and unscrew the fuel filter counter- clockwise. Dispose of the old filter in accordance with local environmental regulations. Lightly oil the gasket (2) of the new fuel filter. Mount the fuel filter and tighten it by hand.
  • Page 93 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Hose of air intake pipe Red field Reset button Hose Air filter service indicator Ignition lock Operation Start Procedure Step Activity Remove the capsule hood or side trim panel (see chapter 5 En- gine design, page 27). Turn the starting key to position I.

  • Page 94: Renewing The Poly V Belt And Checking The Function Of The Switch-Off Unit

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Step Activity If there is no reaction, check the following: ▪ Electrical part; cable connections, etc. ▪ Indicator ▪ Function of the maintenance switch. Mechanical air filter maintenance display Generate a vacuum by sucking forcefully at the hose end. The red field (1) engages.
  • Page 95 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Overview — Removing the poly v-belt Cylinder screw Tension pulley Pulley Procedure — Removing the poly v belt Step Activity Unscrew one cylinder screw (1) from the pulley (3). Push back the tension pulley (2) and lock it using the cylinder screw (1).
  • Page 96 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Angle lever Switch-off pin Procedure — Checking the function of the switch-off unit of the belt moni- toring system Step Activity Release the piston with the tension pulley (1) by removing the cylinder screw. ▪ The piston with the tension pulley is pushed out of the housing by spring pressure.
  • Page 97 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Step Activity Position the poly v belt centrally on the pulley of the fan wheel, the tension pulley (2) and the pulley at the bottom. Overview — Centering the pulley Cylinder screw Square opening Procedure — Centering the pulley Step Activity Lightly secure the pulley with a cylinder screw (1) without plac-...

  • Page 98: Faults

    Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults Trouble shooting General troubleshooting notes If the cases listed below have been worked through but the fault continues to persist, please contact your nearest Hatz service station. The engine does not start or does not start immediately, but it can be turned with the starter.
  • Page 99 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults Possible causes Remedy Chapter Poly v belt torn. Renew the poly v belt. 8.2.17 Renewing the poly v belt and checking the function of the switch-off unit, page 94 Insufficient compression: ▪ Wrong tappet clear- Check the tappet clearance 8.2.13 Check and ance.
  • Page 100 Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 The starter does not switch on and the engine does not turn. Possible causes Remedy Chapter Irregularities in the electrical equipment: Battery and/or other Check the electrical equipment 3.2.4 Electrical cable connections are and its components or contact equipment, page incorrectly connected.
  • Page 101 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults Possible causes Remedy Chapter ▪ Engine temperature Check the cooling air guides 8.2.7 Cleaning too high. for contamination or other im- the cooling fan, pairments. cooling fins and oil cooler, page Engine switches off spontaneously during operation. Possible causes Remedy Chapter...
  • Page 102 Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Possible causes Remedy Chapter ▪ Engine temperature Check the cooling air guides 8.2.7 Cleaning too high. for contamination or other im- the cooling fan, pairments. cooling fins and oil cooler, page Irregularities in the electrical equipment: ▪...

  • Page 103: Emergency Start

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults The engine loses power and speed, and black smoke emerges from the ex- haust Possible causes Remedy Chapter Dirty air filter unit. Check the degree of dirt con- 8.2.11 Maintain- tamination of the air filter, and ing the dry air fil- clean or renew it if necessary.
  • Page 104 Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 This may be necessary if the vehicle stops at a critical location (railroad crossing or intersection). When a monitoring element of the automatic switch-off is activated, the cor- responding indicator lights up. After shutting down the engine, the indicator remains lit for approx.
  • Page 105 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults Overview Emergency start lever Seal wire Procedure Step Activity Check the oil level (see chapter 7.9 Check the oil level, page 58). Remove the capsule hood or side trim panel (see chapter 5 Engine design, page 27) Place a suitable tool, such as a screwdriver, behind the emer- gency start lever (2) and tear the seal wire (3) between the emergency start lever and the housing screw with a forceful...

  • Page 106: Storage And Disposal

    Storage and disposal 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Storage and disposal 10.1 Storing the machine Safety notes 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. ▪...
  • Page 107 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Storage and disposal Storing the machine for a lengthy period Take the following measures if you intend to take the machine out of service for a lengthy period (3-12 months): Step Activity Drain the fuel tank until it is nearly empty and fill with FAME*- free fuel.

  • Page 108: Disposing Of The Machine

    Storage and disposal 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Recommissioning Step Activity Remove all covers. Check the cables, hoses and lines for cracks and leak tightness. Check the engine oil level. Install the battery in accordance with the Operator's Manual for the machine. The brand new engine can normally be stored for up to 12 months.

  • Page 109: Installation Declaration

    The manufacturer: Motorenfabrik Hatz GmbH & Co.KG Ernst-Hatz-Straße 16 D-94099 Ruhstorf a. d. Rott hereby declares that the incomplete machine: product description: Hatz diesel engine Type designation and as of serial number: 2L41=10214; 2L41=15310; 3L41=10314; 4L41=10414; 4L42=14010; 2M41=10514; 2M41=15410; 3M41=10614; 4M41=10714; 4M42=14310 satisfies the following basic safety and health protection requirements in acc.

  • Page 110: Declaration Of The Manufacturer

    Declaration of the manufacturer 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Declaration of the manufacturer The following "Manufacturer's declaration of compliance with regulation (EU) 2016/1628" only applies to engines with an engine family designation in ac- cordance with section 1.5 (see next page). The corresponding engine family designation is noted on the engine type plate (see chapter 4.2 Engine type plate, page 23).
  • Page 111 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Declaration of the manufacturer Declaration by manufacturer on compliance with Regulation (EU) 2016/1628 The undersigned: Manfred Wührmüller, Head of Quality Management GMQ Hereby declares that the following engine type/engine family (*) complies in all respects with the requirements of Regulation (EU) 2016/1628 of the European Parliament and of the Council ( Commission Delegated Regulation (EU) 2017/654 ( ), Commission Delegated Regulation (EU)
  • Page 112 Motorenfabrik Hatz GmbH & Co. KG Ernst-Hatz-Str. 16 94099 Ruhstorf a. d. Rott Deutschland Tel. +49 8531 319-0 Fax. +49 8531 319-418 marketing@hatz-diesel.de www.hatz-diesel.com 0000 433 402 13 - 02.2020 Printed in Germany CREATING POWER SOLUTIONS.

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