Hatz Diesel 3H50 User manual

CREATING POWER SOLUTIONS.
MANUAL
for diesel engine
Hatz Diesel
3H50 | 4H50
www.hatz-diesel.com

3H50, 4H50 / 06 - Rev. 00 Table of contents
HATZ 3Manual
Table of contents
1 Legal notices........................................................................................................5
2 General information.............................................................................................6
3 Safety ....................................................................................................................7
3.1
General information..............................................................................................................7
3.1.1 Intended use ........................................................................................................................7
3.1.2 Machine user or machine manufacturer obligations ............................................................8
3.1.3 Representation of safety notes ............................................................................................9
3.1.4 Meaning of safety symbols.................................................................................................10
3.2 Safety notes .......................................................................................................................12
3.2.1 Operational safety..............................................................................................................12
3.2.2 Machine-specific safety instructions for operation .............................................................15
3.2.3 Machine-specific safety instructions for maintenance work ...............................................16
3.2.4 Electrical equipment...........................................................................................................18
3.3 Labels.................................................................................................................................19
4 Technical data....................................................................................................21
4.1
Engine information and filling quantities ............................................................................21
4.2 Engine type plate ...............................................................................................................25
4.2.1 Engine serial number .........................................................................................................26
4.3 Engine oil ...........................................................................................................................27
4.4 Coolant...............................................................................................................................28
4.5 Fuel ....................................................................................................................................32
5 Engine overview ................................................................................................34
5.1
Designation of components................................................................................................34
5.2 Fuses .................................................................................................................................44
5.3 Hatz Smart Panel (HSP) ....................................................................................................45
5.3.1 Main menu .........................................................................................................................45
5.3.2 Menu – Current Values ......................................................................................................49
5.3.3 Menu – General Settings ...................................................................................................50
6 Transport, installation and commissioning ....................................................53
6.1
Transport............................................................................................................................53
6.2 Installation notes ................................................................................................................56
6.3 Preparations for commissioning.........................................................................................57
6.4 Filling engine oil (first filling) ...............................................................................................58
6.5 Filling the cooling system...................................................................................................59
6.6 Venting the fuel system......................................................................................................61
7 Operation and use .............................................................................................63
7.1
Safety notes .......................................................................................................................63
7.2 Performing tests .................................................................................................................64
7.3 Starting the engine.............................................................................................................65
7.4 Switching off the engine.....................................................................................................68

Table of contents 3H50, 4H50 / 06 - Rev. 00
4HATZ Manual
7.5
Check the oil level..............................................................................................................70
7.6 Refueling............................................................................................................................72
7.7 Regenerating the diesel particulate filter............................................................................73
8 Maintenance .......................................................................................................79
8.1
General maintenance instructions......................................................................................79
8.2 Maintenance work..............................................................................................................80
8.2.1 Maintenance plan...............................................................................................................80
8.2.2 Additional work on the Silent Pack.....................................................................................83
8.2.3 Check the intake area of the combustion air......................................................................86
8.2.4 Check the cooler fins for contamination.............................................................................88
8.2.5 Check the cooling system ..................................................................................................89
8.2.6 Changing the engine oil and oil filter..................................................................................92
8.2.7 Clean the radiator fins........................................................................................................98
8.2.8 Checking the poly v belt...................................................................................................101
8.2.9 Replacing the poly v belts ................................................................................................105
8.2.10 Change the oil separator of the crankcase ventilation .....................................................110
8.2.11 Check the screw connections ..........................................................................................111
8.2.12 Drain the water separator.................................................................................................111
8.2.13 Changing the fuel prefilter................................................................................................113
8.2.14 Changing the main fuel filter ............................................................................................115
8.2.15 Servicing the air filter (optional)........................................................................................118
8.2.16 Change the coolant..........................................................................................................120
8.2.17 Draining the charge air cooler..........................................................................................123
8.2.18 Resetting the service interval indicator ............................................................................124
9 Faults ................................................................................................................127
9.1
Troubleshooting ...............................................................................................................127
9.2 Diagnostic trouble codes in case of engine malfunctions ................................................130
9.3 Start support.....................................................................................................................131
10 Storage and disposal ......................................................................................136
10.1
Storing the machine .........................................................................................................136
10.2 Disposing of the machine.................................................................................................138
11 Declaration of incorporation...........................................................................139
12 Declaration of the manufacturer ....................................................................140

3H50, 4H50 / 06 - Rev. 00 Legal notices
HATZ 5Manual
1 Legal notices
Contact data
© 2023
Motorenfabrik Hatz
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. [phone]
Fax [phone]
[email protected]
www.hatz-diesel.com
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. The same conditions apply to distribution of this manual to third par-
ties in digital form.
Original manual
This manual has been translated into multiple languages.
The German version is the original manual. All other language versions are
translations of the original manual.
Revision
Version Date Name
06 - Rev. 00 06.06.2023 GMV / ef

General information 3H50, 4H50 / 06 - Rev. 00
6HATZ Manual
2 General information
Information on the document
This manual was created with due care. It is exclusively intended to offer a
technical description of the machine and to provide instructions on commis-
sioning, operating and maintaining the machine. When operating the ma-
chine, the applicable standards and legal regulations as well as any in-house
regulations apply.
Before commissioning, during operation and before maintenance work is be-
gun on the machine, read this manual carefully and keep it close by for
ready access.
Machine
This manual describes the following machine.
Machine name HATZ diesel engine
Type number 3H50T, 3H50TI, 3H50TIC, 3H50TICD, 4H50TI,
4H50TIC, 4H50TICD
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the over 500 HATZ service stations. Trained spe-
cialists there will repair your machine with Hatz original spare parts and
with 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
Installation of unsuitable spare parts can lead to problems. We cannot ac-
cept liability for direct damage or secondary damage that results from this.
We therefore recommend the use of Hatz original spare parts. These parts
are manufactured according to strict Hatz specifications and achieve maxi-
mum operational reliability through their perfect fit and functionality. The or-
der number can be found in the enclosed spare parts list or on the Internet
at: www.hatz-diesel.com
Exclusion of liability
The manufacturer cannot be held liable for personal injury, damage to prop-
erty or damage to the machine itself caused by improper use, foreseeable
misuse, or failure to follow or adequately follow the safety measures and
procedures described in this manual. This also applies to changes made to
the machine and the use of unsuitable spare parts.
Modifications, which serve the technical improvements, are reserved.

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 7Manual
3 Safety
3.1 General information
Introduction
This chapter contains the information you need to work safely with this ma-
chine.
To prevent accidents and damage to the machine, it is imperative that these
safety instructions be followed.
Read this chapter carefully before beginning work.
3.1.1 Intended use
Intended use
The machine described in this manual fulfills the following functions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See chapter 11 Declaration of incorpo-
ration, page 139.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine in which the engine is installed.
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.
Use according to the intended purpose also includes observance of the in-
structions in this Operator's Manual.
Foreseeable misuse
The following is considered to be foreseeable misuse:
▪ Any use that varies from or extends beyond the uses specified above.
▪ Failure to comply with the instructions given in this manual.
▪ Failure to comply with the safety instructions.
▪ Failure to immediately eliminate malfunctions that impact safety before
continuing work with the machine (working with the machine when it is not
in perfect condition, either functionally or in terms of safety).
▪ Failure to perform the necessary inspection and maintenance work.
▪ Any unauthorized modification of or removal of safety equipment.
▪ Use of spare parts and accessories that are unsuitable or have not been
approved by HATZ.
▪ Fuel other than specified in the instructions.
▪ Operation in flammable or hazardous environments.

Safety 3H50, 4H50 / 06 - Rev. 00
8HATZ Manual
▪ Operation in closed-off or poorly ventilated rooms.
▪ Operation in an aggressive atmosphere (e.g., high salt content) without
further measures for corrosion protection.
▪ Installation of the machine on movable machines (e.g., vehicles, trailers)
without HATZ approval.
▪ Improper operation at variance with DINISO3046 -1 and DINISO8528
(climate, load, safety).
Residual risks
Residual risks result during daily use and in association with maintenance
work.
These residual risks will be pointed out in chapter 3.2.2 Machine-specific
safety instructions for operation, page 15 and in chapter 3.2.3 Machine-
specific safety instructions for maintenance work, page 16 as well as in the
further contents of the manual, directly in front of the descriptions or operat-
ing instructions concerned.
3.1.2 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.
It is prohibited to start the engine before it is fully installed.
In addition, please note that it is prohibited to start up the machine before it
has been determined that the machine into which this engine is installed ful-
fills all safety-related requirements and legal regulations.
User obligations
The operator is obliged to only operate the machine when it is in perfect con-
dition. The operator must check the condition of the machine before use and
ensure that any defects are eliminated before it is taken into service. Operat-
ing the machine while identified defects exist is not permitted. The operator
must also ensure that all persons who work on the machine are familiar with
the contents of this manual.
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood this manual or must possess the qualifications neces-
sary for working with this equipment, acquired in training/instructional cour-
ses. No one may work with the machine without the necessary qualifications,
even if for just a brief period.
The operating and maintenance personnel must not be under the influence
of drugs, medication or alcohol.

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 9Manual
All work performed on the machine must be in compliance with the informa-
tion provided in this manual.
Storing this manual
This manual is an integral component of the machine (also when being
sold). It must be stored in the direct vicinity of the machine and be accessi-
ble to personnel at all times.
3.1.3 Representation of safety notes
Overview
This machine has been designed and built according to state-of-the-art tech-
nology and the recognized safety standards. Despite these precautions,
risks exist when operating the machine and during maintenance work.
These risks are identified in this manual by means of safety notes.
The safety notes precede the relevant description or operating step.
Structure of the safety notes
The safety notes consist of:
▪ Danger symbol
▪ Signal word
▪ Description of the danger
▪ Possible consequences
▪ Preventative measures
General danger symbol
The general danger symbol is used to identify the danger of personal injury.

Safety 3H50, 4H50 / 06 - Rev. 00
10 HATZ Manual
Signal words
Signal words identify the magnitude of the risk and the seriousness of possi-
ble injury:
Danger symbol/
signal word
Meaning
DANGER
This signal word is used to indicate imminently
dangerous situations which, if not avoided, will
lead to serious injury or death.
WARNING
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to serious injury or death.
CAUTION
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to minor or moderate injury.
CAUTION
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
NOTICE
This signal word indicates additional useful infor-
mation, such as operating tips and cross refer-
ences.
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this manual.
Symbol Meaning
Smoking, fire, and open flames are prohibited!
Warning of personal injury!
Warning of hot surfaces!
Warning of hot surfaces!
(Alternative)

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 11Manual
Symbol Meaning
Warning of flammable substances!
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 operator.
i
Additional information that is useful to the reader.

Safety 3H50, 4H50 / 06 - Rev. 00
12 HATZ Manual
3.2 Safety notes
3.2.1 Operational safety
Introduction
This chapter contains all of the important safety instructions for personal pro-
tection and for safe and reliable operation. Additional, task-related safety in-
structions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury or danger of property dam-
age due to failure to comply with this manual and the safety
instructions contained therein.
▪ As the operator of the machine, you must ensure that all
people working on the machine are familiar with the content
of this manual.
▪ Before working on the machine, read this manual carefully,
paying special attention to the safety notes.
▪ Fulfill all required safety conditions before working on the
machine.
▪ Follow all general safety instructions as well as the specific
task-related safety instructions contained in the individual
chapters.
Using the machine
▪ Only operate the machine for the purposes described in chapter 3.1.1 In-
tended use, page 7.
Compliance with other regulations
▪ The applicable regulations of the relevant professional associations must
be observed.
▪ Comply with the regulations concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regula-
tions also apply when operating the machine.
Personal protective equipment
During operation and maintenance of the machine, personal protective
equipment must be available and must be used if necessary. The use of per-
sonal protective equipment is specified in the description of the operating
steps.

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 13Manual
Personal protective
equipment
Pictogram Function
Safety shoes Safety shoes offer protection
against:
▪ Slipping
▪ Falling objects
Hearing protection Hearing protection offers protec-
tion against ear injuries due to
excessive and constant noise.
Safety gloves Safety gloves protect the hands
against injury, e.g., from battery
acid.
Safety goggles
(with side protection)
Safety goggles protect the eyes
from flying objects (e.g., dust
particles, spraying liquids, spray-
ing acid).
Fine dust mask A fine dust mask protects the
wearer against particulate pollu-
tants.
Working clothes Wear close-fitting working
clothes. It must not restrict the
wearer's freedom of movement,
however.
Warning labels and information signs on the machine
The warning labels and information signs on the machine must be followed
(see chapter "Labels" 3.3 Labels, page 19).
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
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians (see chapter 2 General in-
formation, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.

Safety 3H50, 4H50 / 06 - Rev. 00
14 HATZ Manual
Safety equipment
Safety equipment must not be modified and must not be rendered ineffective
during normal operation.
General safety instructions
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in this manual.
▪ Heed the warnings on the machine and in this manual.
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪ The personnel must have read and understood this manual
or must possess the qualifications necessary for working
with this equipment, acquired in training/instructional cour-
ses.
▪ Only qualified personnel is permitted to operate and main-
tain this machine.
▪ Failure to comply will cause the warranty to become void.
WARNING
Danger of injury from failure to follow the Operating Instruc-
tions and from performing unauthorized tasks on the ma-
chine.
▪ Follow all instructions.
▪ Do not perform activities for which no qualification is avail-
able. Contact properly trained personnel if necessary.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another loca-
tion can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist (see chapter 6.1 Transport,
page 53).

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 15Manual
3.2.2 Machine-specific safety instructions for operation
Introduction
The machine can pose residual risks during operation. To eliminate these
risks, all persons working on the machine must follow the general and ma-
chine-specific safety instructions.
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.
If the engine is installed in a machine or assembled with other machines to
form a machine, it is prohibited to start the engine before it has been deter-
mined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations.
Safe operation
▪ Before switching on the machine, ensure that no one can be injured when
the machine is started up.
▪ During machine operation, ensure that unauthorized persons do not have
access to the area in which the machine has an impact.
▪ Parts of the exhaust gas system and the surface of the engine become hot
during operation. Risk of injury from touching hot parts! Let the engine cool
before maintenance.
▪ Do not refuel during operation.
Faults
▪ Immediately eliminate faults that compromise safety.
▪ Switch off the machine and do not take into service again until all faults
have been eliminated.
Safety instructions for operation
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.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.

Safety 3H50, 4H50 / 06 - Rev. 00
16 HATZ Manual
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off and has cooled
down.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
DANGER
Danger of fire from hot exhaust gas system.
If inflammable materials come into contact with the exhaust gas
flow or the hot exhaust gas system, these materials can ignite.
▪ Keep inflammable materials away from the exhaust gas sys-
tem.
▪ Do not operate the engine (exhaust flow or hot exhaust gas
system) in the direct vicinity of combustible materials.
3.2.3 Machine-specific safety instructions for maintenance work
Introduction
The machine can pose residual risks during maintenance. To eliminate
these risks, all persons working on the machine must follow the general and
machine-specific safety instructions.
Maintenance intervals
▪ Strictly adhere to the maintenance intervals.
▪ Check the safety equipment regularly to ensure it is in good condition and
functioning properly.
▪ Check connections, cables and fasteners regularly to ensure they are in
good condition.
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians. We recommend that you
work with one of the over 500 HATZ service stations.

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 17Manual
Replacing parts
▪ When replacing defective components, we recommend that you use Hatz
original spare parts (see chapter 2 General information, page 6).
▪ 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.
▪ Check the entire machine for foreign bodies; remove any foreign bodies.
Safety instructions for maintenance work
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.
▪ Use halogen-free, cold cleaners with a high flash point for
cleaning.
▪ Comply with manufacturer's instructions.
WARNING
Danger of injury from compressed air and dust particles.
Eye injuries can occur when cleaning with compressed air.
▪ Wear safety goggles.
CAUTION
Danger of injury from ignoring the maintenance instruc-
tions.
▪ Only perform maintenance work when the engine is
switched off.
▪ For engines with an electric starter:
Disconnect the negative battery terminal.
Protect the starting key from unauthorized access.

Safety 3H50, 4H50 / 06 - Rev. 00
18 HATZ Manual
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.
▪ Do not place tools or other metal objects on the battery.
▪ Before performing work on the electrical equipment, always
disconnect the negative battery terminal.
▪ Never swap the plus (+) and negative (–) battery terminals.
▪ When installing the battery, first connect the plus cable and
then the negative cable.
▪ When removing the battery, first disconnect the negative
cable and then the plus cable.
▪ It is imperative to prevent short circuits and mass contact of
current carrying cables.
▪ If faults occur, check the cable connections for good con-
tact.
DANGER
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪ Keep batteries away from open flames and incendiary
sparks.
▪ Do not smoke when working with batteries.

3H50, 4H50 / 06 - Rev. 00 Safety
HATZ 19Manual
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
▪ Protect your eyes, skin, and clothing from corrosive battery
acid.
▪ Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.
▪ Promptly replace defective indicator lamps.
▪ Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪ When performing welding work on the machine, disconnect the battery
and place the ground clamp of the welding equipment as close as possible
to the welding area. Disconnect the plug connectors to the engine control
unit and to the voltage regulator of the three phase alternator.
NOTICE
▪ We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
3.3 Labels
Warning labels and information signs on the engine
sign Meaning
Engine specification Silent Pack
CAUTION!
Danger of injury from rotating parts.
▪ Only operate the engine when all
covers are installed.

Safety 3H50, 4H50 / 06 - Rev. 00
20 HATZ Manual
sign Meaning
or
Warning of hot surfaces!
Cleaning with a high pressure
cleaner is prohibited!
▪ Do not spray the Hatz instrument
box with a high-pressure water jet.
Warning labels and information signs on the battery (option)
sign Meaning
12 3
456
7
1.Fire, sparks, open flames and
smoking are prohibited: avoid
causing sparks when working with
cables and electrical machines.
Avoid short-circuits.
2.Follow the instructions on the bat-
tery and in the battery user man-
ual.
3.Keep children away from acid and
batteries.
4.Danger of explosion: A highly ex-
plosive electrolytic gas is created
when batteries are charged.
5.Wear safety goggles when filling.
6.Danger of chemical burns: Battery
acid is highly corrosive. Therefore,
wear safety gloves and eye pro-
tection. Do not tilt the battery; acid
may spill out of the vent openings.
7.Do not dispose of the battery with
the household trash.
8.Take the used battery to a collec-
tion center.