Hatz 2W35 Instruction Manual

INSTRUCTION BOOK 33 INCLUDES SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION-IGNITION ENGINES INCLUDES SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES 2W35 3W35 4W35 4W35T

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. Use of this engine in the intended manner presupposes compliance with the maintenance and repair instructions laid down for it. Noncompliance leads to engine breakdown. Please do not fail to read this operating manual before starting the engine for the first time. This will help you to avoid accidents, ensure that you operate the engine correctly and assist you in complying with the maintenance intervals in order to ensure long-lasting, reliable performance. Please follow all maintenance references carefully including the schedule for 2008 and later EPA certified nonroad compression-ignition engines and for 2008 and later CARB certified off-road engines to prevent our environment. Please pass this Instruction Manual on to the next user or to the following engine owner. The worldwide HATZ Service Network is at your disposal to advise you, supply with spare parts and undertake servicing work. You will find the address of your nearest HATZ service station in the enclosed list. Use only original spare parts from HATZ. Only these parts guarantee a perfect dimensional stability and quality. The order numbers can be found in the enclosed spare parts list. Please note the spare parts kits shown in Table M00. We reserve the right to make modifications in the course of technical progress. MOTORENFABRIK HATZ GMBH & CO KG 1

when operating the engine 4 2. Description of the engine 6 3. General notes 10 3.1. Technical data 10 3.2. Transport 11 3.3. Instructions for installation 11 3.4. Load on engine 11 3.5. EPA/CARB-type plates 12 3.6. Emission-related installation instructions 13 4. Operation 13 4.1. Before initial start-up 13 4.1.1. Engine oil 13 4.1.2. Coolant 14 4.1.3. Fuel 16 4.2. Starting the engine 18 4.2.1. Preparations for starting 18 4.2.2. Electric starter 19 4.3. Stopping the engine 20 5. Maintenance 22 5.1. Maintenance chart 22 5.2. Maintenance every 8 - 15 operating hours 24 5.2.1. Check engine oil level 24 5.2.2. Check combustion air intake area 24 5.2.3. Check air cleaner maintenance indicator 25 5.2.4. Check radiator fins for contamination 25 5.2.5. Check coolant level 25 Page 5.3. Maintenance every 250 operating hours 26 5.3.1. Change engine oil 26 5.3.2. Check water trap 26 5.3.3. Clean the radiator fins 27 5.3.4. Check screw connections 28 5.3.5. Check the Vee belt 28 5.4. Maintenance every 500 operating hours 29 5.4.1. Replace primary fuel filter 29 5.4.2. Replace the engine oil filter 30 5.4.3. Air cleaner maintenance 31 5.5. Maintenance every 1000 operating hours 34 5.5.1. Renew the fuel filter 34 5.6. Maintenance: every 4 years 35 5.6.1. Replacement of coolant 35 6. Malfunctions – causes – remedies 37 7. Work on the electrical system 41 8. Storage out of use 41 SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES 43 SUPPLEMENTAL INFORMATION TO THE OWNER’S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES 57 3 Contents This symbol identifies important safety precautions. Please comply with these most carefully in order to avoid any risk of injury to persons or damage to materials. General legal requirements and safety regulations issued by the competent authorities or industrial accident insurers must also be complied with.

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. A few general points concerning operating safety should nonetheless be noted. Depending on the engine's operating and installation conditions, equipment manufacturers and their users may have to fit safety or protective devices in order to prevent improper use. Examples: – Exhaust system components as well as the surface of the engine will naturally be hot and must not be touched while the engine is running or until it has cooled down after being stopped. – Incorrect wiring or improper operation of the electrical system may cause sparking and must there- fore be avoided. – Provide protection against contact with rotating parts once the engine is connected to the driven equipment or machine. HATZ protective guards are available for the belt drive of the cooling fan and alternator drive systems. – Always observe the start-up information in the operating instructions before starting the engine. – Mechanical starting devices should not be operated by children or persons deficient in physical strength. – Check that all safety devices are in place before starting the engine. – Ensure that operation, maintenance and repair of the engine are undertaken by suitably trained personnel only. – Protect the starter key against unauthorised use. – Do not run the engine in closed or insufficiently ventilated rooms. Do not breathe in emissions – danger of poisoning! – Also fuel and lubricants could contain poisonous components. Please follow the appropriate instructions of the mineral oil producer. – Radiator protection fluids are detrimental to health. Thus, they may only be stored in closed original containers and in a place inaccessible to non-authorized persons. Eye and skin contact must be avoided. Comply with the manufacturer’s instructions 4

– The engine must be stopped before performing any maintenance, cleaning or repair work. – It is essential to stop the engine before refilling the fuel tank. Never refuel near a naked flame or sparks which could start a fire. Don’t smoke. Don’t spill fuel. – Keep explosive materials as well as flammable materials away from the engine because the exhaust gets very hot during operation. – Never spill consumables, such as fuel, oil or radiator protection fluid over hot engine components. The fluid might catch fire. – Work on the cooling system must not be performed while the engine is warm - risk of scalding! The cooling system is pressurized. – Wear close-fitting clothing only when working on the engine while it is running. Please don’t wear necklaces, bracelets or any other objects which you could get caught with. – 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. – We accept no liability for damage resulting from improper modifications to the engine. Regular servicing in accordance with the details provided in this Instruction Book is essential to keep the operating reliably and to ensure the exhaust quality of the engine. When in doubt, consult your local HATZ service station before starting the engine. 5

6 MOTORENFABRIK HATZ KG D-94099 RUHSTORF MADE IN GERMANY 11 17 16 15 13 12 1 2 3 4 5 6 7 8 10 9 14 1 Operator’s side 1 Speed adjustment lever 2 Type plate 3 Coolant pump 4 Oil dipstick 5 Oil filler cap 6 Drain plug for coolant 7 Oil drain plug (governor side) 8 Engine mountings (optional equipment) 9 Oil drain plug (operator’s side) 10 Engine oil filter 11 Water drain plug on fuel filter 12 Oil pressure switch 13 Fuel filter with water trap 14 Dry-type air cleaner 15 Combustion air intake port 16 Fuel suction line connector 17 Fuel pre-filter

7 1 Fuel feed pump 2 Fuel return line 3 Stop lever (optional equipment) 4 Exhaust silencer 5 Exhaust gas outlet 6 Electrical starter 7 Central plug for electrical system 8 Oil drain plug (exhaust side) 9 Voltage regulator 10 Fan (optional equipment) 11 Radiator (optional equipment) 12 Coolant supply to engine 13 Coolant return to radiator and thermostat 14 Temperature switch 15 Coolant expansion tank (optional equipment) 16 Vent line to expansion tank 17 Cylinder head cover 1 2 3 4 5 6 7 8 11 14 13 12 9 15 16 10 17 2 Exhaust side

8 MOTORENFABRIK HATZ KG D-94099 RUHSTORF MADE IN GERMANY 1 2 3 4 5 6 7 8 10 15 14 13 9 11 17 19 12 16 18 3 Operator’s side 1 Speed adjustment lever 2 Type plate 3 Coolant pump 4 Oil dipstick 5 Fan (optional equipment) 6 Hydraulic pump drive (optional equipment) 7 Flange for additional hydraulic pump (optional equipment) 8 Oil drain plug (governor side) 9 Engine mountings (optional equipment) 10 Oil drain plug (operator’s side) 11 Oil filler cap 12 Engine oil filter 13 Water drain plug on fuel filter 14 Oil pressure switch 15 Fuel filter with water trap 16 Dry-type air cleaner 17 Combustion air intake port 18 Fuel suction line connector 19 Fuel pre-filter

1 Fuel feed pump 2 Fuel return line 3 Stop lever or stop solenoid (optional equipment) 4 Turbocharger 5 Exhaust flange 6 Electric starter 7 Oil drain plug (exhaust side) 8 Central plug for electrical system 9 Voltage regulator 10 Coolant supply to engine 11 Coolant return to radiator and thermostat 12 Temperature switch 13 Exhaust manifold 14 Connector for vent line to expansion tank (coolant) 15 Cylinder head cover 3 4 5 6 7 1 2 14 12 11 10 9 8 15 13 4 Exhaust side

determining factor. 2) Exceeding these limits causes engine breakdown. Type 2W35 3W35 4W35 4W35T Design Fluid-cooled four-stroke diesel engine Combustion air normal intake turbo- charged Combustion system Direct injection Number of cylinders 2 3 4 4 Bore / stroke mm 70/90 70/90 70/90 70/90 Displacement cm3 692 1038 1384 1384 Lubricating oil capacity l. approx. 2.5 1) 3.4 1) 4.4 1) 4.4 1) Difference between “max” and “min” levels l. approx. 1.2 1) 1.4 1) 1.6 1) 1.6 1) Lubricating oil consumption (after running in) approx. 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. 4.6 5.4 6.7 6.7 Direction of rotation, looking at the flywheel counterclockwise Max. admissible tilt angle in operation (with lub-oil level at max. marking of dip- stick with the engine in horizontal position) max. 30° in any direction 2) Weight (incl. electric starter, air-cleaner and exhaust silencer) without radiator kg approx. 74 89 107 111 Battery capacity 12V / 55 Ah

points. The eyebolts are used to safely transport the engine incl. the optional equipment. They are not suited and not approved for hoisting complete machines. 6 Make sure that only suitable hoisting equipment with a sufficient lifting ca- pacity is used for transport! 3.3. Instructions for installation The „Manual for Selection and Installation of En- gines“ contains all the information you need if your engine has not yet been installed on or in the equipment it is intended to drive, or set up in its correct operating position. You can obtain a copy of this manual from your nearest HATZ service station. 7 The admissible forces and torques on the speed adjusting lever and the stop lever should be observed as exceeding them can lead to damage to the stops and inner governor parts. 3.4. Load on engine See supplemental information for EPA certified engines, Page 43; resp. supplemental informa- tion for California regulations for off road engines, Page 57. 11

fuel label There are two EPA/CARB- type plates applied for the identification of the engine. The type plates are placed on the crankcase (chapt. 2). They include the following emission control in- formation (Figure 8a): Label 1/2 8a ➀EPA/CARB-Engine Family Number ➁engine type/spec. (only for special equipment) /Fuel Delivery Timing ➂engine number (also stamped on crankcase, Fig. 9) ➃max. engine rated speed ➄build date ➅displacement ➆rated power ➇“constant speed only” (if requested) ➈“variable speed” (if requested) Every engine is equipped with an additional loose engine type plate. If the original type plate on the engine is not readily visible after the engine is installed in the equipment then the second loose type plate must be attached on the equipment in such a manner that it is readily visible to an average person. ➀ ➁ ➂ ➃ ➄ ➅ ➆ ➇ ➈ For any offer as well as spare parts orders it is necessary to mention the following data (also see spare parts list, page 1): ➁engine type/spec. (only for special equipment) ➂engine number ➃max. engine rated speed The layout is identical for constant-speed and variable speed application. Attention: If the engine was certified for constant-speed application and shall be used so, the field "con- stant-speed only" is marked with “X”. If the engine was certified for variable speed ap- plication and shall be used so, the field "variable speed" is marked with “X”. Always install the engine for its intended applica- tion in order to comply with EPA and CARB emission regulation requirements. Label 2/2 8b The engine must be operated with “LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY”. The label also states the applicable emission- related power category of the engine. EMISSION CONTROL INFORMATION LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY Power category: ❏< 8 kW / ❏ 8-19kW / ❏ 19-37kW / ❏37-56 kW PM Standard: 0.3 g/kWh Label 2/2 12

If there was no fuel tank mounted to the engine, the label has to be permanently attached to the equipment near the fuel inlet. 9 Engine serial number stamped on crankcase. 3.6. EMISSION-RELATED INSTALLATION INSTRUCTIONS See supplemental information for EPA certified engines, Page 43; resp. supplemental informa- tion for California regulations for off road engines, Page 57. LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY 4. Operation 4.1. Before initial start-up The engines are normally delivered to the cus- tomers without fuel, oil and coolant filling! 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. 4.1.1. Engine oil Oil quality All premium oils which meet at least one of the following specifications are suitable: for naturally-aspirated engines ACEA – B2 / E2 or superior API – CF / CF-4 / CG-4 or superior. for turbo engines ACEA – B3 / E2 or superior API – CF / CF-4 / CG-4 or superior If engine oil of a poorer quality is used, reduce oil change intervals to 150 operating hours. 13

temperatures where the engine is to be started from cold. The engine must be in a horizontal position be- fore adding oil or checking the oil level. 11 – Remove oil drain plug and pour in engine oil. For the quantity of lubricant required, refer to Chapter 3.1. 12 – For oil level inspection, remove the dipstick and wipe it dry using a lint-free, clean piece of cloth; then insert it to its stop and pull it out again. – Read the oil level on the dipstick; if necessary, add oil until the level reaches the max. mark. 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: These radiator protection fluids provide effi- cient protection against corrosion, especially in the case of aluminium engines, and against freezing. Moreover, the coolant's boiling point is essentially increased and limescale is prevented from forming in the cooling system. Manufacturer Product description BASF Glysantin® G 30 TOTAL Glacelf Plus 14

subject to previous consultation with the factory. Properties of the radiator protection fluids: Important! Mixing of the above-mentioned products is admissible, however, the specifications of the lower-grade product shall apply in this case. A replacement interval of 2 years must be complied with. In the cooling system, mixed radiator protec- tion fluids are characterized by their brown colour. Glysantin® G 30 and Glacelf Plus are available from every HATZ Service station. Product Properties Glysantin® G 30 nitrite-, amine-, phosphate- and silicate-free. Identification colour: violet Replacement interval: every 4 years Glacelf Plus nitrite-, amine- and phos- phate-free. Contains silicate. Identification colour: blue- green Replacement interval: every 2 years Processing the coolant Radiator protection fluids are detri- mental to health. Thus, they may only be stored in closed original containers and in a place inaccessible to non-authorized persons. Eye and skin contact must be avoided. Comply with the manufacturer’s instructions. – Add water to the coolant before pouring it in the cooling circulation. Clean water which is not excessively hard must be used for processing. Tap water which contains as little salts, minerals and suspend- ed matter as possible is well suited. The mixing ratio of the coolant should not fall below or exceed the following concentration: An insufficient concentration of coolant increas- es the risk of corrosion in the cooling system, as well as the risk of freezing, depending on the prevailing climate conditions. If the portion of radiator protection fluid exceeds 50 percent by volume, this will impair the cool- ing effect as well as the anti-freeze protection. Thus, if the concentration of the radiator protec- tion fluid falls below or exceeds the specified values, this may cause serious damage to the engine. 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. Radiator protection fluid Water Frost- resistant down to approx. min. 35 percent by volume 65 percent by volume -22 °C max. 50 percent by volume 50 percent by volume -40 °C 15

freeze protection fluid deteriorates long-term, it must be checked yearly using a commercial an- tifreeze tester. If the concentration is too low, no matter at which service interval, the coolant must be replaced as described in Chapter 5.6.1. Filling the cooling system Work on the cooling system must not be performed while the engine is warm - risk of scalding! The cooling system is pressurized. 13 – Open cap 1. – Pour in coolant until the level reaches the MAX mark on the expansion tank. – Tighten cap 1 by hand. – After the engine has warmed up, check coolant level again. When the engine is at a standstill and has cooled down, the coolant level must be visible between the tank’s MIN and MAX marks; if the engine is warm, the level may be slightly above the MAX mark. – Check cooling system for leakage; if necessary, re-tighten hose clamps. Add coolant While the engine is warm, the cap of the expansion tank must not be opened Risk of scalding. The cooling system is pres- surized. – First stop the engine and allow it to cool down. Then put a piece of cloth over cap 1 of the ex- pansion tank and open cap carefully (Fig. 13). – Add coolant until the level is between the MIN and the MAX mark (Fig. 13). – Tighten cap 1 by hand. 16

Never refuel close to open flames or flammable sparks, don’t smoke. Use only pure fuel and clean replenishing vessels. Don’t spill the fuel. 14 Pos. 1 = Fuel feed line Pos. 2 = Fuel return line All diesel fuels sold as fuel and complying with the following minimum specification can be used: EN 590 or BS 2869 A1 / A2 or ASTM D 975-1D / 2D Low temperature resistance At low temperatures, the viscosity of Diesel fuel increases. This may result in clogging of the fuel system. Thus, winter fuel must be used at out- side temperatures below 0 °C, or petroleum must be added in time. Bleeding the injection system Air may enter into the injection system if the fuel tank is completely emptied or while the primary fuel filter or the fuel filter are replaced. To bleed the system, proceed as described be- low, depending on whether the fuel tank is arranged in HIGH position above the fuel supply pump, or in LOW position below the fuel supply pump: Fuel tank HIGH – Fill fuel tank completely with diesel fuel. – Start the engine as described in Chapter 4.2. Note: The fuel system is bled automatically when the engine is started. To this effect, starting may take longer than usual. To save the starter and the battery, do not actuate the starter continuously for more than 15 to 20 seconds at a time. Make pauses of approx. 1 minute between the various starting attempts. Should the engine fail to start even at the 2nd attempt, locate and eliminate the trouble (Chapter 6). Lowest ambient temperature when starting, in °C Paraffin content for: Summer fuel Winter fuel 0 up to –10 –10 up to –15 –15 up to –20 –20 up to –30 20 % 30 % 50 % – – – 20 % 50 % 17

If the fuel tank is located at an even lower level, a manual fuel pump or an electrical supply pump must be used for bleeding. Models with manual fuel pump 15 – Place a suitable vessel under the filter to trap escaping fuel. – Open the vent screw 1 by approx. one turn. 16 – Compress and release rubber ball repeatedly, until fuel escapes from the vent screw 1. – Close vent screw 1, then actuate rubber ball another two times. 1 – Start the engine as described in Chapter 4.2. Models with electrical supply pump – With this model, first turn the starter key to position I and wait for approx. one minute, Chapter 4.2.2. During this waiting time, the fuel system is largely bled by means of the electrical supply pump. – Start the engine as described in Chapter 4.2. 4.2. Starting the engine Do not run the engine in closed or in- sufficiently ventilated rooms – danger of poisoning! Before the engine is started, al- ways make sure that nobody is in the danger area (moving parts on engine or machinery) and that all safety guards are in place. 17 Never use any spray starting aids. 050 145 00 18

– If possible, disengage the engine from any driven equipment. The auxiliary equipment should always be placed in neutral. 18 – Set speed control lever to a position between 1/2 START and max. START, according to re- quirements. Selecting a lower engine speed will reduce smoke when starting. 4.2.2. Electric starter To save the starter and the battery, do not actuate the starter continuously for more than 15 to 20 seconds at a time. Make pauses of approx. 1 minute between the various starting attempts. Should the engine fail to start even at the 2nd attempt, locate and eliminate the trouble (Chapter 6). 19 – Insert the key to its stop and turn it to position I. – Battery charge pilot lamp 2 and oil pressure warning 3 must light up. – Turn starter key to position II. – As soon as the engine runs, release the starter key. It must return to position I by itself and remain in this position during operation. The battery charge pilot lamp and oil pressure warning must go out immediately after start- ing. Indicator light 1 is on when the engine is in operation, Fig. 19. – The air cleaner maintenance indicator 5 only goes on during operation to show that the air cleaner needs cleaning or replacement (Fig. 19, Chapter 5.4.3). 19

soon as the coolant becomes inadmissibly hot. Stop the engine immediately and trace and eliminate the cause of the problem, Chap. 6. – Always turn the starter key back to position 0 before re-starting the engine. The repeat lock in the ignition lock prevents the starter motor from engaging and possibly being damaged while the engine is still running. Important! If a start protection module is installed, the starter key has to be returned to position 0 for at least 8 seconds if the engine has failed to start before a further attempt to start the engine can be made. Preheating device with automatic heating timer (optional equipment) The preheating light 6 lights up additionally at temperatures below 0° centigrade (Fig. 19). – After the light has gone out, start the engine without delay. Automatic electrical shutdown system (optional equipment) This is characterized by a brief flashing of all pilot lamps once the starter key has been turned to position I, figure 19. Important! If the engine cuts out immediately after starting or switches off by itself during operation, a monitoring element in the automatic shutdown system has tripped. The corresponding indicator light (Fig. 19, positions 2 - 4) will come on. After the engine has stopped, the indicator re- mains lit for another approx. 2 minutes. The electrical device then switches off automatically. The display lights up again after the starter key has been turned back to position 0, and then to position I again. Trace and eliminate the cause of the operating fault before trying to restart the engine (see Chapter 6). The indicator light goes out when the engine is next started. Even with automatic shutdown monitoring the oil level must be checked every 8 – 15 operating hours (Chapter 5.2.1. and 5.2.5.). 20

If operation of the engine is interrupted for any reason, or at the end of the working day, the starter key should be kept out of reach of unauthorised per- sons. Stop via engine speed setting lever 20 – Move the speed adjustment lever back to the STOP position. The engine cuts out. Stop via the stop lever (optional equipment) 21 – Press the stop lever down towards STOP and hold it until the engine has come to a stand- still. When the engine is not running any longer, release stop lever. The stop lever is returned automatically to its operating position START via a spring (Fig. 21). 22 The charge 2 and oil pressure pilot lamps 3 come on. – Turn the starter key to the 0 position and pull it out. The pilot lamp lights must then go out. 23 Engines equipped with stop solenoid can also be stopped by turning the starter key back to position 0. 3 2 6 21

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. Before starting the engine, ensure that there are no persons in the danger area close to the en- gine or equipment. 5.1. Maintenance chart 22 Maintenance interval Maintenance work required Chap. 8-15 Every 8 – 15 operating hours, or before each daily start-up • Check oil level. • Check combustion air intake area. • Check air cleaner maintenance indicator. • Check radiator fins for contamination. • Check coolant level. 5.2.1. 5.2.2. 5.2.3. 5.2.4. 5.2.5. 250 Every 250 operating hours • Change engine oil. • Check for contamination of primary fuel filter, renew if necessary. • Check water trap on the fuel filter. • Clean the radiator fins. • Check screw connections. • Check the Vee belt (optional equipment). 5.3.1. 5.4.1. 5.3.2. 5.3.3. 5.3.4. 5.3.5. 500 Every 500 operating hours • Replace primary fuel filter. • Replace the engine oil filter. • Maintenance of air cleaner. 5.4.1. 5.4.2. 5.4.3. 1000 Every 1000 operating hours • Renew the fuel filter. 5.5.1. Every 2 – 4 years • Replacement of coolant. (every 2 years in case Glacelf Plus is used) (every 4 years in case Glysantin® G 30 is used) 5.6.1.

plied with every engine. This stick-on label should be provided in an easily visible position on the engine. However, the maintenance inter- vals are subject to maintenance chart shown in this chapter. For new or reconditioned engines, the following must always be carried out after first 50 operat- ing hours: – Replace engine oil and oil filter, Chap. 5.3.1. and 5.4.2. – Examine screw connections, Chap. 5.3.4. For short operating periods: replace engine oil and oil filter after 12 months at the latest, regardless of the number of operating hours. 23

operating hours 5.2.1. Check engine oil level When checking the oil level, the engine should be standing level, and must not be running. – Remove any dirt in the dipstick area. 25 – For oil level inspection, remove the dipstick and wipe it dry using a lint-free, clean piece of cloth; then insert it to its stop and pull it out again. – Check the dipstick oil level and, if necessary, add oil to the max. mark, Chapter 4.1.1. Attention! If the engine is operated while the oil level is below the min. mark, it will be damaged. 5.2.2. Check combustion air intake area Severe contamination is a sign that there are large amounts of dust in the atmosphere and the air cleaner maintenance intervals should be reduced, Chapter. 5.4.3. 26 27 – Check air intake port 1 – depending on version – for coarse contamination, such as leaves, lots of dust etc., if necessary, clean (Fig. 26 and 27). 24

check the dust ejector valve for free passage; if necessary, remove deposited dust by com- pressing the valve. 5.2.3. Check air cleaner maintenance indicator (optional equipment) 29 – Increase the engine speed briefly to maximum level and watch out for the pilot lamp 5 to go on. When it does go on, check the dry air cleaner, Chapter 5.4.3. 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. 30 – Check radiator fins for coarse contamination, such as leaves, lots of dust etc., if necessary, clean them (Chapter 5.3.3.). Attention! Seriously contaminated radiator fins may result in engine overheating. 5.2.5. Check coolant level 31 MAX 25

cooled down, the coolant level must be visible between the tank’s MIN and MAX marks; if the engine is warm, the level may be slightly above the MAX mark (Fig. 31). Loss of coolant Work on the cooling system must not be effected while the engine is warm – risk of scalding! The cooling system is pressurized. In most cases, loss of coolant is due to leakage in the cooling system. – 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: If the cooling system is perfectly tight, loss only occurs if the coolant is boiling and thus is pressed out of the cooling system via the cap on the expansion tank. This may be due to contamination in the radiator fin area (Chapter 5.2.4) or to engine overload. Add coolant – refer to Chapter 4.1.2. 5.3. Maintenance every 250 operating hours 5.3.1. Change engine oil The engine must be standing level and be switched off. Only change the oil when the engine is warm. Danger of scalding from hot oil! Trap the old oil and dispose of it in accordance with local legislation. 32 – Take out oil drain plug 1 and allow the oil to drain completely. Possible draining positions, refer to Chapter 2. – Clean the oil drain plug 1, fit a new washer 2, insert and tighten. – Add engine oil, Chapter 4.1.1. 5.3.2. Check water trap The water trap inspection interval depends exclusively on the water contained in the fuel and on the care applied in refuelling. It may be admissible to extend the intervals, or it may be necessary to considerably shorten the intervals. 26

in a transparent vessel. If the drain plug is not easily accessible, an ex- tension piece of hose can be slipped on the plug. – If an insufficient amount of liquid leaves the tank, release additionally plug 2. As water is heavier than diesel fuel, first the water, then the fuel will escape. This is indicated by the clearly visible separating line. – If finally only fuel leaves through the port, the drain plug 1 can be closed again. – Subsequently, re-tighten plug 2. Note: If starting appears difficult, bleed the injection system (Chapter 4.1.3). 1 2 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. – Place a vessel below the radiator to collect any contamination. Dry contamination 34 – Blow-clean radiator fins – depending on the degree of soiling – either using compressed air or rinse them using a water jet (first from item 1, then from item 2). Do not use a high-pressure jet. Damp or oily contamination – Spray-coat the whole area with an appropriate cleaning solution according to the manufactur- er’s specification, and subsequently clean by means of a water jet. Do not use a high-pres- sure jet. Note: Do not use gasoline or acidic cleaning agents. – Determine the cause of oiling and eliminate leakage. MAX 27

– Check the tightness of all threaded connec- tions and take up slack if necessary, provided that these can be reached during maintenance work. 35 36 The adjusting screws at the engine governor and on the injection system are sealed with lacquer and are not to be tightened or adjusted, Figs. 35 and 36. 5.3.5. Check the Vee belt (optional equipment) – Check the Vee belt over its entire circumference for cracks or damage; if necessary, replace. 37 – Check the belt tension by pressing it down with your thumb; if necessary, re-tighten. Re-tighten the Vee belt 38 – Release the screws 1-3 and pull three-phase alternator 4 outwards. – Re-tighten the screws and check the belt tension. 28

39 – Release the screws 1-3 and push three-phase alternator 4 to the inside. – Remove Vee belt and replace it by a new one. – Pull the three-phase alternator 4 outwards and re-tighten the screws (Fig. 38). – Check the belt tension. Note: Check tension of new belts once more after approx. 15 minutes of operation. 5.4. Maintenance every 500 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. Important: Keep the entire area clean so that no dirt reaches the fuel. – Place a suitable vessel under the filter to trap escaping fuel. – Close the fuel supply line. 40 – Pull fuel supply line 1 off the primary fuel filter 2 at both sides. – Insert the new primary fuel filter. 29

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. – Check fuel filter and lines for leakage after a short test run. Note: If starting appears difficult, bleed the injection system (Chapter 4.1.3). 5.4.2. Replace the engine oil filter It makes sense to replace the filter cartridge simultaneously with the engine oil change. The engine must be placed horizontally and be at a standstill. Danger of scalding from hot oil! Trap the old oil and dispose of it in accordance with local legislation. Horizontal replaceable-cartridge filter (standard equipment) 41 – Release replaceable-cartridge lubricant filter by means of a strap wrench or a similar tool, and remove it. 42 – Clean sealing surface 1 thoroughly. – Slightly grease the packing ring 2 of the new replaceable-cartridge filter. – Turn-in replaceable-cartridge filter and tighten it by hand. Vertical replaceable-cartridge filter (optional equipment) – Remove air cleaner cover including filter cartridges. Chapter 5.4.3. 43 – Release replaceable-cartridge lubricant filter by means of a strap wrench or a similar tool. Alternately, an appropriate tool can also be slipped on the hexagon 1. 30

tent shown in the illustration. In this position, a valve releases the oil return flow into the crankcase, whereupon the replaceable-car- tridge filter is emptied. After a waiting period of approx. 30 seconds, the replaceable-car- tridge filter can be unscrewed completely. 45 – Clean sealing surface 1 and moulding 2 thor- oughly. – Slightly grease the packing ring 3 of the new replaceable-cartridge filter. – 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). – After a short test run, check replaceable- cartridge filter for leakage; if necessary, re-tighten. – Check oil level and, if necessary, replenish. 5.4.3. Maintenance of air cleaner It makes sense to clean the filter cartridge (two each in case of three- and four-cylinder engines) only if the maintenance indicator signals the ne- cessity. Apart from that, the cartridge must be replaced after a period of 500 service hours. 46 – Release the toggle-type fasteners. 31

lift it and remove it (arrow 2). 48 – Pull filter cartridges carefully off the filter support. – Clean the filter support and the air cleaner cover. Make sure that dirt or other foreign matter cannot enter the engine air intake port 1. 49 – Check seal 1 and rubber pad 2 for damage, de- 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 Dry contamination 50 – Use compressed air to blow through the filter cartridge from the inside outwards, until no further dirt emerges. Important! The pressure must not exceed 5 bar. 32

– 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. Important! The slightest damage to the paper filter rules out its being used any longer. – Re-assemble the filter cartridge in the reverse order of work. 51 – Make sure the filter cartridge is mounted on the correct end. 042 746 00 52 – Position air cleaner cover at the bottom of the filter support (arrow 1), then tilt it towards the engine (arrow 2). 53 – Before fastening the toggle-type fasteners, align the air cleaner cover on the left with the filer support. 33

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. Important! Maximum cleanliness is required to prevent dirt from entering the fuel system. Fuel particles may damage the injection system. Replace the fuel filter 54 – Close the fuel lines at the filter housing. 55 – Place a suitable vessel under the filter to trap escaping fuel. – Release drain plug 1 to drain the fuel. 56 – Release the fuel filter using a strap wrench or a similar tool, and remove it. 1 34

able-cartridge filter – Assemble replaceable-cartridge filter and tighten it by hand. – Bleed the injection system (Chapter 4.1.3). – After a short test run, check fuel filter for leak- age; if necessary, re-tighten it by hand. 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. Work on the cooling system must not be effected while the engine is warm – risk of scalding! The cooling system is pressurized. Collect the coolant and eliminate it according to the statutory regulations. 58 – First stop the engine and allow it to cool down. Then put a piece of cloth over cap 1 of the ex- pansion tank and open cap carefully. – Provide a vessel to collect the used coolant. 35

drain coolant. 60 – 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). – Fill the cooling system (Chapter 4.1.2.). 36

Malfunction Possible causes Remedy Chap. 6.1. Engine will not start or start is delayed, although it can be turned over with the starter. At low temperatures. Speed control lever is in stop or idle position. Stop lever in stop position. No fuel reaching injection pump. Compression too low: -Valve clearances incorrect -Cylinder bore and/or piston ring wear Unit Injector System not operating correctly Lower starting temperature limit exceeded. Machinery not uncoupled. Defective preheating system (optional equipment). Fuel highly viscous due to inadequate resistance to low temperatures. Set lever to „START“-position Add. fuel. Bleed the injection system. Check entire fuel supply system carefully. If no fault is found: -supply line to engine -primary fuel filter -Check the fuel filter. See workshop manual. See workshop manual. See workshop manual. Operate preheating system (optional equipment). Disengage engine from machinery or equipment if possible. See workshop manual. Check that clear fuel - i.e. without turbidity - leaves from the discon- nected fuel supply line. If the fuel is highly viscous, either warm up the engine or drain the entire fuel supply system. Pour in a temperature-resistant fuel mix. 4.2.1. 4.1.3. 4.1.3. 5.4.1. 5.5.1. 4.2.2.

stop solenoid or automatic electrical shutdown system (optional equipment) 6.2. Engine fires but does not run. With automatic electrical shutdown installed (optional equipment) 6.3. Starter motor does not operate or engine does not turn over. Starting speed too low: -Engine oil is too viscous. -Battery charge is insufficient. Solenoid faulty and/or fault in the electrical system. Speed control lever not moved far enough towards START. Equipment not disengaged. Primary fuel filter or fuel filter clogged. Fuel supply interrupted. One of the automatic shutdown’s monitoring elements has initiated a stop signal. (See also Chapter 6.4.). Fault in the electrical system: - Battery and/or other cables incorrectly connected. - Cable connections loose and/or oxidised. - Battery faulty and/or flat. - Starter faulty. - Faulty relays, monitoring elements, etc. Change lubricating oil and refill with a different grade of oil. Check the battery; consult a spe- cialist workshop if necessary. See workshop manual. Move lever to START position. Disengage engine from equipment if possible. Replace filter. Check all fuel supply components systematically. Locate the responsible monitoring element and clear the fault, or con- tact a HATZ service station. Check electrical system and its component. See also the workshop manual. 5.3.1. 4.1.1. 4.2.1. 5.4.1. 5.5.1.

operation. With automatic electrical shutdown installed (optional equipment) 6.5. Engine output and speed both drop. Fuel supply interrupted -Tank has run empty. -Primary fuel filter or fuel filter clogged. Mechanical faults One of the automatic shutdown’s monitoring elements has initiated a stop signal. Monitoring element for: -oil pressure too low -engine temperature too high -AC generator or three-phase alternator (optional equipment) faulty. Malfunction signal from overvolt- age and polarity reversal protec- tion in voltage regulator: -Battery and/or other cable con- nections incorrectly connected. -Cable connections loose. Fuel supply interrupted: -Tank has run empty. -Primary fuel filter or fuel filter clogged. -Tank insufficiently ventilated. -Pipe connections leaky. -Speed control lever does not remain in desired position. Add fuel. Change fuel filter. Contact a HATZ service station. Locate the responsible monitoring element and clear the fault, or con- tact a HATZ service station. -Check lubricating oil supply. -Radiator fins soiled or cooling system function otherwise im- paired. -Coolant level. -Check belt tension (only in case of models with belt-driven fan). See workshop manual. Check electrical equipment and the components thereof. Add fuel. Replace filter. Ensure sufficient ventilation of tank. Check pipe screw couplings for leakage. Lock the lever into position. 4.1.3. 5.4.1. 5.5.1. 4.2.2. 5.2.1. 5.2.4. 5.2.5. 5.3.5. 4.1.3. 5.4.1. 5.5.1.

black smoke from exhaust. 6.7. Engine gets very hot. Engine temperature pilot lamp goes on. Air cleaner contaminated. Valve clearances incorrect. Unit Injector System not functioning. Too much lubricating oil in engine. Insufficient cooling effect: -Radiator fins soiled. -Loss of coolant. -Vee belt broken or slack (only in case of models with belt-driven fan). -Engine overloaded. Clean or renew the air cleaner. See workshop manual. See workshop manual. Drain off lubricating oil as far as upper mark on dipstick. Clean the radiator fins. Check cooling system for leakage and eliminate cause - in case of doubt, contact the HATZ Service station. Subsequently, replenish coolant. Check the Vee belt Reduce load. 5.4.3. 5.3.1. 5.3.3. 4.1.2. 5.3.5.

system Batteries generate explosive gases. Keep them away from naked flame and sparks which could cause them to ignite. Do not smoke. Protect eyes, skin and clothes against the corrosive battery acid. Pour clear water over acid splashes immediately. In case of emergency call a doctor. Do not place any tools on top of the battery. Always disconnect the negative (–) terminal of the battery before working on the electrical system. – Do not confuse the positive (+) and negative (–) terminals of the battery. – When fitting the battery, first connect the positive lead, then the negative lead. Negative terminal to ground = engine case. – When removing, first disconnect the negative lead, then the positive lead. – Always take care to avoid short-circuits and earth (ground) contact of live cables. – If malfunctions occur, first of all check that cable connections make good contact. – Replace a failed pilot lamp without delay. – Do not remove the starter key while the engine is running. – Do not disconnect the battery while the en- gine is running. Electric voltage peaks can cause damage to electronic components. – Do not splash electrical system with water jet or pressure jet during engine cleaning. – When carrying out welding work on the en- gine or equipment, fit the ground terminal of the welding equipment as close to the welding point as possible and disconnect the battery. The connecting plug for the voltage regulator must be removed. The relevant circuit diagrams are enclosed with the engine if it is equipped with an electrical system. Additional circuit diagrams can be supplied to order. HATZ assumes no liability for electrical systems which have not been carried out acc. to HATZ circuit diagrams. 8. Storage out of use The new engine can normally be stored dry for up to one year. In very humid climates or coastal regions, the protective treatment is sufficient for up to about 6 months. For longer periods of storage, please contact your nearest HATZ service station. 41

EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. EPA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS. 43

SUPPLEMENTAL INFORMATION TO THE OWNERS MANUAL FOR 2008 AND LATER EPA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. The following supplemental information is furnished for EPA Nonroad Compression Ignition Engines which are certified according to 40 CFR Part 89 and Part 1039. This information contains the following specific items: • EPA-related engine parts and engine operating conditions • Maintenance instructions for EPA-related engine parts • Emission control system and adjustments • Warranty statement • Emission-related installation instructions 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 • Cold air duct • Turbocharger ( including wastegate ), ducting • Unit Injectors • Oil filler cap 44

• 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. 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. If such a condition occurs, you should contact the nearest HATZ authorized Service Center for necessary repairs. The engine is designed and adjusted to operate most efficiently at the following conditions: • Air temperature of 25° C ( 77° F) • Atmospheric pressure of 100 kPa (14.5 psi) • Relative humidity of 30 % Operation of the engine at conditions other than above will affect performance and exhaust emissions. Normally the equipment manufacturer takes this into account during the design of the machine and your equipment will perform within specifications over a wide range of climatic conditions. However if you must operate your equipment under very unusual climatic conditions, please contact your nearest Hatz distributor for advice. 45

The following minimum intervals are being adopted for adjustment, cleaning, repair, or replacement of following components: At 1,500 hours, and 1,500-hours intervals thereafter: • Fuel injector tips (cleaning only) At 3,000 hours, and 3,000-hours intervals thereafter: • Fuel injector The exhaust quality of the engines can be influenced by the execution (the quality of execution) of above described maintenance work. 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). No adjustments are needed or possible. 46

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. Your emission control system includes: • Air cleaner housing • Cold air duct • Turbocharger ( including wastegate ), ducting • Unit Injectors • Oil filler cap • PCV ( 'positive crankcase ventilation' ) connection assembly • Exhaust manifold • Emission Control Information Labels Where a warrantable condition exists, Motorenfabrik Hatz will repair your engine at no cost to you including diagnosis, parts and labor. 47

The 2008 and later EPA certified nonroad compression ignition engines are warranted for 1500 hours of operation or two years of use, whichever first occurs. If any emission related part on your engine is defective, the part will be repaired or replaced by Motorenfabrik Hatz. OWNERS WARRANTY RESPONSIBILITIES: • As the engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Motorenfabrik Hatz recommends that you retain all receipts covering maintenance on your engine, but Motorenfabrik Hatz cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. • 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. • You are responsible for presenting your engine to a Motorenfabrik Hatz authorized service center as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact HATZ DIESEL OF AMERICA, Inc. at (262)-544-0254. HATZ DIESEL SUPPLEMENTAL WARRANTY FOR 2008 AND LATER EPA CERTIFIED ENGINES. 48

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 • Turbocharger ( including wastegate ), ducting • Unit Injectors • Oil filler cap • PCV ( 'positive crankcase ventilation' ) connection assembly • Exhaust manifold • Emission Control Information Labels 49

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 coverage conditions, after the date of delivery to the original retail purchaser and Hatz will at their option, repair or replace at Hatz's sales headquarters, or at a point designated by Hatz, any part or parts which shall appear to the satisfaction of Hatz upon inspection at such point, to have been defective in material or workmanship. • Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part. • Any replacement part which is equivalent in performance and durability may be used in non-warranty maintenance or repairs and will not reduce the overall engine warrranty obligations of Hatz. However, Hatz is not responsible for failure of such replacement parts or failure of any other parts directly caused by failure of such replacement parts. • This warranty does not obligate Hatz to bear any transportation charges in connection with the repair or replacement of defective parts. This warranty is transferrable to subsequent owners, only under the named warranty coverage conditions. • In order to obtain service under this warranty, the retail purchaser should contact Hatz Diesel of America, Inc. at (262)-544-0254 for information and the nearest service center. The retail purchaser will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, nor for the repair or replacement of warranted parts if the work is performed at an authorized Hatz service center. If other engine components are damaged due to a failure of the above-listed warranted parts still under warranty, these other engine components will also be repaired or replaced at no charge. • This warranty shall not apply to any engine which shall have been installed or operated in a manner not recommended by Hatz, nor to any engine which shall have been repaired, altered, neglected, or used in any way which, in the opinion of Hatz, adversely affects its performance, nor to any engine in which parts not authorized by Hatz have been used, which parts or the use of which have damaged or caused defects in or otherwise adversely affected the engine or its performance, nor to normal maintenance service or replacement of normal service items. Hatz reserves the right to modify, alter, and improve any engine or parts without incurring any obligation to replace any engine or parts previously sold with such modified, altered, or improved engine or parts. 50

“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.” EQUIPMENT-LABELLING REQUIREMENTS: FUEL LABEL (Chapter 3.5) The fuel label has to be permanently attached to the equipment. In case of an engine mounted fuel tank, every engine is equipped with an additional fuel label. Otherwise, there are two loose fuel labels available with the engine. If the original fuel label is not readily visible after the engine is installed in the equipment then the second loose fuel label must be attached on the equipment in such a manner that it is readily visible to an average person. 51

Following are the instructions to properly install the exhaust system and related components consistent with the EPA emission regulation requirements. Electrical starter The electrical starter is fitted in connection with washers, hex.-nuts and Allen screws. Preparations: • Disconnect the negative pole 1 of the battery. Dismantling: • Remove in numerical sequence 2...7. Assembly: • Assemble in reverse sequence. 52 2W35 · 3W35 · 4W35 (T)

protection plate. Dismantling: • Remove in numerical sequence 1...7. Assembly: • Assemble in reverse sequence. 53 2W35 · 3W35 · 4W35 (T)

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: Specification 1: Adding a 20-centimeter linear extension to the exhaust pipe 54 Version 1

55 Version 2 Engine type Ø d (mm) Version 1 HATZ-Ident. Nr. Version 2 HATZ-Ident. Nr. Clamp HATZ-Ident. Nr. 2W35 38 830 857 000 830 858 00 037 409 00 3W35 38 830 857 000 830 858 00 037 409 00 4W35 (T) 38 830 857 000 830 858 00 037 409 00

FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT AND EMISSION-RELATED INSTALLATION INSTRUCTIONS. 57

SUPPLEMENTAL INFORMATION TO THE OWNER´S MANUAL FOR 2008 AND LATER CALIFORNIA REGULATIONS FOR HEAVY-DUTY OFF-ROAD ENGINES. The following supplemental information is furnished for California Heavy-Duty Off-Road Engines. This information contains the following specific items: • CARB-related engine parts and engine operating conditions • Maintenance instructions for CARB-related engine parts • Emission control system and adjustments • Warranty statement • Emission-related installation instructions 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 • Cold air duct • Turbocharger ( including wastegate ), ducting • Unit Injectors • Oil filler cap • PCV ( 'positive crankcase ventilation' ) connection assembly 58

• 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. If such a condition occurs, you should contact the nearest HATZ authorized Service Center for necessary repairs. The engine is designed and adjusted to operate most efficiently at the following conditions: • Air temperature of 25° C ( 77° F) • Atmospheric pressure of 100 kPa (14.5 psi) • Relative humidity of 30 % Operation of the engine at conditions other than above will affect performance and exhaust emissions. Normally the equipment manufacturer takes this into account during the design of the machine and your equipment will perform within specifications over a wide range of climatic conditions. However if you must operate your equipment under very unusual climatic conditions, please contact your nearest Hatz distributor for advice. MAINTENANCE SCHEDULE-CARB-RELATED PARTS. The following minimum intervals are being adopted for adjustment, cleaning, repair, or replacement of following components: At 1,500 hours, and 1,500 hours intervals thereafter: • Fuel injector tips (cleaning only) At 3,000 hours, and 3000 hours intervals thereafter: • Fuel Injectors 59

execution) of above described maintenance work. 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). No adjustments are needed or possible. 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. The Motorenfabrik Hatz GmbH & Co. KG must warrant 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. Your emission control system may include parts such as the fuel-injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, the Motorenfabrik Hatz GmbH & Co. KG will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts, and labor. 60

The 2008 and later heavy-duty off-road engines are warranted for 1500 hours of operation or two years of use, whichever first occurs. If any emission-related part on your engine is defective, the part will be repaired or replaced by Motorenfabrik Hatz GmbH & Co. KG. OWNER´S WARRANTY RESPONSIBILITIES. • 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. KG cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. • As the heavy-duty off-road engine owner, you should however be aware that Motorenfabrik Hatz GmbH & Co. KG may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. • Your engine is designed to operate on low sulfur diesel fuel or ultra-low sulfur diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. • You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a Motorenfabrik Hatz authorised dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, you should contact Hatz Diesel of America, Inc. at (262)-544-0254. 61

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: • Air cleaner housing • Cold air duct • Turbocharger ( including wastegate ), ducting • Unit Injectors • Oil filler cap • PCV ( 'positive crankcase ventilation' ) connection assembly • Exhaust manifold • Emission Control Information Labels 62

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) months after the date of delivery to the original retail purchaser and Hatz will at their option, repair or replace at Hatz's sales headquaters, or at a point designated by Hatz, any part or parts which shall appear to the satisfaction of Hatz upon inspection at such point, to have been defective in material or workmanship. • Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part. • Any replacement part which is equivalent in performance and durability may be used in non-warranty maintenance or repairs and will not reduce the overall engine warrranty obligations of Hatz. However, Hatz is not responsible for failure of such replacement parts or failure of any other parts directly caused by failure of such replacement parts. • This warranty does not obligate Hatz to bear any transportation charges in connection with the repair or replacement of defective parts. This warranty is transferrable to sub- sequent owners within the original twenty-four (24) months time period. • In order to obtain service under this warranty, the retail purchaser should contact Hatz Diesel of America, Inc. at (262)-544-0254 for information and the nearest service center. The retail purchaser will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, nor for the repair or replacement of warranted parts if the work is performed at an authorized Hatz service center. If other engine components are damaged due to a failure of the above-listed warranted parts still under warranty, these other engine components will also be repaired or replaced at no charge. • This warranty shall not apply to any engine which shall have been installed or operated in a manner not recommended by Hatz, nor to any engine which shall have been repaired, altered, neglected, or used in any way which, in the opinion of Hatz, adverse- ly affects its performance, nor to any engine in which parts not authorized by Hatz have been used, which parts or the use of which have damaged or caused defects in or otherwise adversely affected the engine or its performance, nor to normal maintenance service or replacement of normal service items. Hatz reserves the right to modify, alter, and improve any engine or parts without incurring any obligation to replace any engine or parts previously sold with such modified, altered, or improved engine or parts. 63

“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.” EQUIPMENT-LABELLING REQUIREMENTS: FUEL LABEL (Chapter 3.5) The fuel label has to be permanently attached to the equipment. In case of an engine mounted fuel tank, every engine is equipped with an additional fuel label. Otherwise, there are two loose fuel labels available with the engine. If the original fuel label is not readily visible after the engine is installed in the equipment then the second loose fuel label must be attached on the equipment in such a manner that it is readily visible to an average person. 64

Following are the instructions to properly install the exhaust system and related components consistent with the EPA emission regulation requirements. Electrical starter The electrical starter is fitted in connection with washers, hex.-nuts and Allen screws. Preparations: • Disconnect the negative pole 1 of the battery. Dismantling: • Remove in numerical sequence 2...7. Assembly: • Assemble in reverse sequence. 65 2W35 · 3W35 · 4W35 (T)

protection plate. Dismantling: • Remove in numerical sequence 1...7. Assembly: • Assemble in reverse sequence. 66 2W35 · 3W35 · 4W35 (T)

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: Specification 1: Adding a 20-centimeter linear extension to the exhaust pipe 67 Version 1

68 Version 2 Engine type Ø d (mm) Version 1 HATZ-Ident. Nr. Version 2 HATZ-Ident. Nr. Clamp HATZ-Ident. Nr. 2W35 38 830 857 000 830 858 00 037 409 00 3W35 38 830 857 000 830 858 00 037 409 00 4W35 (T) 38 830 857 000 830 858 00 037 409 00

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.