Hatz 2-4L41C Manual
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Hatz 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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  • 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...
  • Page 4 Table of contents 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Checking the water separator....................  56 Check the oil level...................... 57 Maintenance ......................  59 General maintenance instructions .................. 59 Maintenance work...................... 60 8.2.1 Maintenance notice label .................... 60 8.2.2 Maintenance plan ...................... 62 8.2.3 Checking the intake area of the combustion air..............

  • Page 5: Notices

    All rights reserved! Copyright The copyright for this manual rests entirely with Motorenfabrik HATZ, Ruh- storf. 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.

  • Page 6: General Information

    HATZ tools. The global HATZ service network is at your disposal to ad- vise 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...

  • Page 7: Safety

    Any other use is not intended and therefore not permitted. Violations com- promise 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 in- tended.

  • 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.

  • 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.

  • 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.
  • Page 13 The warning labels and information signs on the machine must be followed (see chapter "Labels" 3.3 Labels, page 20). 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. Maintenance work...
  • 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.

  • 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

    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 Manual HATZ...
  • 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 ▪ 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.

  • 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 59) 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...
  • 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...

  • 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...

  • Page 25: Fuel

    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). HATZ Manual...
  • 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)
  • 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...
  • 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...
  • 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...
  • 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...

  • Page 33: Transport, Assembly And Commissioning

    ▪ 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.

  • Page 34: Installation Notes

    ▪ 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. ▪ Comply with all notices and warning labels on the engine and keep them in a legible condition.

  • Page 35: Preparations For Commissioning

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Transport, assembly and commissioning 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.
  • Page 36 Transport, assembly and commissioning 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 37: Operation And Use

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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 38: Performing Tests

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 39: Pumping Fuel With The Manual Fuel Pump

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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 40 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 41: Setting The Speed Control

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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 42 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 43 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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...
  • Page 44 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Preparation Step Activity Carry out start preparations (see the chapter 7.3 Start prepara- tion, page 38). Move the speed control lever into position "Start" (see the chap- ter Setting the speed control). Move all decompression levers to position "1".

  • Page 45: Starting The Engine

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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 46 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.. Manual HATZ...
  • Page 47 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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".

  • Page 48: Starting The Engine With A Starter

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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...
  • Page 49 Engine oil pressure too low. Danger of engine damage. Stop the engine immediately and check the oil level (see section 7.9 Check the oil level, page 57). Contact HATZ Service if the oil level is correct. Engine temperature display Engine temperature is impermissibly high. Danger of engine damage.
  • Page 50 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 51 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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 97).

  • Page 52: Switching Off The Engine

    ▪ The flash code indicates that the air filter must be cleaned or changed (see chapter 8.2.12 Checking and cleaning the air filter cartridge, page 81). ▪ If a different flash code appears, please contact the nearest Hatz service. NOTICE If the electronics indicate a problem continuously for more than 15 minutes without interruption (flash code - indicator 5), the en- gine switches off automatically.

  • Page 53: Switching Off The Engine (Mechanical)

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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)

  • Page 54: Switching Off The Engine (Electrical)

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 55: Refueling

    The use of fuel that does not meet the specifications can lead to engine damage. ▪ Only use the fuel specified in chapter 4.5 Fuel, page 25. ▪ The use of fuel that does not meet specifications requires approval by Motorenfabrik HATZ (main plant). HATZ Manual...

  • Page 56: Checking The Water Separator

    Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 57: Check The Oil Level

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Operation and use 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).
  • Page 58 Operation and use 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 59: Maintenance

    ▪ Installation of unsuitable spare parts can lead to problems. We cannot ac- cept responsibility for direct damage or secondary damage that results from this.We therefore recommend the use of Hatz original spare parts. ▪ Closely adhere to the maintenance conditions prescribed in this manual.

  • Page 60: Maintenance Work

    ▪ After the necessary maintenance and repair work is completed, perform a function test (test run). ▪ For maintenance work that is not listed and described in the maintenance documentation, please contact your nearest HATZ service station. Maintenance work Safety note...
  • Page 61 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 HATZ Manual...

  • Page 62: Maintenance Plan

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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...

  • Page 63: Checking The Intake Area Of The Combustion Air

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 57 ery day before Check the intake area of the 8.2.3 Checking the in- starting combustion air.
  • Page 64 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 77 Maintain the dry air filter. 8.2.11 Maintaining the dry air filter, page 79 Change the filter cartridge.
  • Page 65 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance NOTICE In case of heavy contamination, shorten the maintenance inter- vals accordingly (see chapter 8.2.2 Maintenance plan, page 62). Overview 2-4M41 and 4M42 2-4L41C and 4L42C Intake opening for combustion air Dust outlet opening Cyclone (option)
  • Page 66 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Electrical air filter maintenance display 2-4L41C and 2-4M41 4L42C and 4M42 Air filter service indicator Mechanical air filter maintenance display Red field Procedure Step Activity For the electrical air filter maintenance display: Manual HATZ...
  • Page 67 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance Step Activity 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. In the engines 4L42C and 4M42, the following flash code indi- cates that maintenance work is required on the air filter ▪...

  • Page 68: Change The Engine Oil

    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 62). Procedure Step Activity Check the supply and exhaust air areas for coarse contamina- tion such as leaves, heavy dust deposits, etc., and clean if necessary (see chapter 8.2.7 Cleaning the cooling fan, cooling...
  • Page 69 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. Hold it with an open-end wrench.

  • Page 70: Checking The Poly V Belt

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 71 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 72: Cleaning The Cooling Fan, Cooling Fins And Oil Cooler

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 73 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 62). Overview — Preparatory activities Baffle plate Preparation —...
  • Page 74 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 75: Checking The Screw Connections

    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...
  • Page 76 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 77: Changing The Fuel Prefilter

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 78 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 79: Maintaining The Dry Air Filter

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 39).
  • Page 80 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 81: Checking And Cleaning The Air Filter Cartridge

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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.
  • Page 82 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 83: Check And Set The Tappet Clearance

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 84 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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).
  • Page 85 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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 86: Changing The Oil Filter

    Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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.

  • Page 87: Change The Main Fuel Filter

    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 88 Collect any escaping fuel and dispose of it according to lo- cal environmental regulations. CAUTION Dirt particles can damage the injection system. ▪ Maintain clean conditions to ensure dirt does not enter the fuel line. Overview 2-4L41C and 2-4M41. Strap wrench (HATZ order no.: 620 307 01) Manual HATZ...
  • Page 89 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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).
  • Page 90 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 Manual HATZ...

  • Page 91: Checking That The Air Filter Maintenance Indicator Is Working Properly

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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.
  • Page 92 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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).

  • Page 93: Renewing The Poly V Belt And Checking The Function Of The Switch-Off Unit

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Maintenance 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.
  • Page 94 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 95 ▪ The switch-off pin (3) must emerge by spring force, or else the machine will not switch off automatically if the belt tears. If there is no reaction, please contact the nearest HATZ service station. Overview — Mounting the poly v-belt...
  • Page 96 Maintenance 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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...

  • Page 97: Faults

    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 98 Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 93 Insufficient compression: ▪ Wrong tappet clear- Check the tappet clearance 8.2.13 Check and...
  • Page 99 2-4L41C, 2-4M41(Z), 4L42C, 4M42 Faults 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 100 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 Engine switches off spontaneously during operation.
  • 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 Irregularities in the electrical equipment: ▪...

  • Page 102: Emergency Start

    Faults 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 103 The oil level must be checked before the emergency opera- tion phase. NOTICE If the emergency operation mode is used, the risk transfers to the operator (the Motorenfabrik HATZ does not accept liabil- ity in this case). ▪ Immediately after the emergency operation phase, deter- mine the cause of the fault.
  • Page 104 Eliminate the emergency situation within a few seconds. Switch off the engine. Immediately after the emergency operation phase: ▪ Determine and remedy the cause of the fault signal (see chapter 9.1 Trouble shooting, page 97). ▪ If necessary, contact your nearest HATZ service station. Manual HATZ...

  • Page 105: Storage And Disposal

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Storage and disposal 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 106 Storage and disposal 2-4L41C, 2-4M41(Z), 4L42C, 4M42 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 107: Disposing Of The Machine

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Storage and disposal 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.

  • Page 108: 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 109: Declaration Of The Manufacturer

    2-4L41C, 2-4M41(Z), 4L42C, 4M42 Declaration of the manufacturer 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).
  • Page 110 Make (trade name(s) of manufacturer): Hatz-Diesel 1.2. Commercial name(s) (if applicable): 1.3. Company name and address of manufacturer: Motorenfabrik Hatz GmbH & Co. KG, Ernst-Hatz-Str. 16, 94099 Ruhstorf a.d. Rott 1.4. Name and address of manufacturer's authorised representative (if any): – 2L/M41-vs, 2L/M41-cs 1.5.
  • Page 111 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.
  • 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 12 - 09.2018 – 3 Printed in Germany CREATING POWER SOLUTIONS.

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