Hatz Diesel 4H50TIC Instruction manual

Workshop Manual
4H50 TIC
439 002 00 - 07.2015e Printed in Germany

Contents
Preface
1. General
Engine illustrations
Technical data
Type plate details
Lubricating oil circuit
Cooling circuit
Sealants and adhesives
Special tools and workshop equipment
2. Additional equipment
Z 01 Main fuel filter
Z 02 Suction hose
Z 03 Oxidation catalytic converter
Z 05 Alternator
Z 05 Starter
Z 06 Engine base
Z 07 Oil cooler
Z 30 Fan

Contents
3. Basic engine equipment
M 01 Cylinder crankcase
M 02 Crankshaft
M 04 Camshaft
M 02 Crankshaft gear wheel
M 01 Connector housing
M 17 Flywheel
M 10 Oil pump
Z 30 Pulley
M 05 Piston and conrod
M 10 Intake manifold
M 01 Oil sump
M 36 Water pump
M 01 Roller tappet
M 07 Cylinder head
M 07 Rocker arm
M 08 Cylinder head cover
Z 05 Glow plugs
M 07 Thermostat, temp. sensor
M 28 Exhaust manifold
M 28 Turbocharger
M 30 Lifting device
M 37 Exhaust gas return
M 14 Injection system
M 31 Crankcase ventilation
4. Tables
Screw tightening torque
Identification on wiring diagrams
HATZ cable marking
Bosch designation for cable marking
Cable harness max.
Cable harness min.
Wiring diagrams
CAN speed adjustment
Analog speed adjustment
Analog speed adjustment
Cable routing
Charge current curve

Preface
This Workshop Manual corresponds to the technical status as stated
on each page (month / year). It has been conceived so that only a trained mechanic (instructed
yearly) can perform all repairs trouble-free.
Notes on how to clean parts etc. have been omitted, as it is taken for granted that this is known
and will be accomplished.
All work may only be performed with the specified or absolutely equivalent tools.
It is a prerequisite that normal "hand tools" are at hand.
With respect to maintenance work, tools, troubleshooting, etc., we refer to the operator's manual.
Only use genuine Hatz original spare parts for repairs!
Only these parts guarantee problem-free dimensional accuracy and quality.
In addition, the general statutory regulations and those of the responsible professional trade as-
sociations apply.
Potential discrepancies due to special equipment are possible and can neither be accounted for in
the Workshop Manual nor in the Spare Parts list.
In case of any difficulties, please contact the nearest HATZ service office.

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1. General

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1 Intake opening for combustion air
2 Rain cap
3 Air filter (option)
4 Dust discharge valve
5 Lifting eyes
6 Fan
7 Oil filter
8 Fine fuel filter
9 Side oil drain screw
10 Starter (low installation position)
11 Electric fuel pump
12 Fuel pre-filter
13 Drain screw on the
fuel pre-filter
14 Engine type plate
15 Dipstick
16 Oil filler screw bottom
17 Crankcase ventilation
14
32
5
5
6
7
8
9
10
11
12
13
16
17
14
15
Engine description
Intake side

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1 Expansion tank for coolant
(option)
2 Oil filler screw top
3 Exhaust gas turbocharger
4 Oxidation catalytic converter
5 Exhaust gas discharge
6 Starter (high installation position)
7 Oil drain screw front
8 Poly v belt
9 Radiator (option)
123
4
5
6
7
8
9
Engine description
Exhaust side

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Technical data
Type 3H50TIC 4H50TIC
Type Liquid-cooled four stroke diesel engine
Combustion system Direct injection,
turbocharger with charge air cooling,
cooled exhaust-gas recirculation
Injection system Bosch common rail
Number of cylinders 3 4
Bore/stroke mm 84/88 84/88
Displacement cm31464 1952
Fill quantity of lubricating oil Approx. ltr. 5.25? 1) 7.0 1)
Difference between "max" and "min"
marking Approx. ltr. ? 1) 1.0 1)
Engine oil consumption
(after running-in period) Max. 1% of fuel consumption, with respect to full load
Engine oil pressure 2.5 bar to 4.5 bar
Coolant quantity with
HATZ standard radiator
and expansion tank Approx. ltr. ? 12.5
Direction of rotation
when looking at flywheel Left
Tappet clearance Automatic tappet clearance compensation
Max. perm. inclination during
continuous operation in every direction: 30° 2)
Weight (incl. radiator and catalytic
converter) without operating fluids approx. kg ? 226
Battery capacity Max. 12 V – 110 Ah / 450 A according to DIN
24 V – 66 Ah / 300 A according to DIN
1) These details must be understood as approx. values.
Relevant is in every case the max. marking on the dipstick.
2) Exceeding these values causes engine damage.

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Engine type plate
EMISSION CONTROL INFORMATION
MOTORENFABRIK HATZ KG ¬ D-94099 RUHSTORF
GMBH
+CO
Model: 4H50TIC – 162J
S/N: 1471014000001 Build: 2014/03
Power: 55,0kW @ 2800 RPM Constant
Displ: 1,95L
Eng.Fam: DHZXL1.95V51
Emission Control System: DFI, DOC, EGR, ECM, TC
Power Category: 37-56kW, PM Standard 0.035
ULTRA LOW SULFUR DIESEL FUEL ONLY. DEL ASSY.
This engine complies with emission regulations for U.S. EPA regulations
MY2014 and California regulations for MY2014 for Non-Road CI engines.
Use in Constant-Speed Applications only.
EU-Type: e197/68PA*2011/88*0699*01 (IIIB)
120R-001022*00
24R-033147
www.hatz-diesel.com
E1
187_44_C_3B
The engine type plate is affixed to the crankcase and includes the following engine information:
1 Model designation of the engine
2 Engine number (serial number of the engine)
3 Engine output (kW) at rated speed (min-1)
4 Displacement (liters)
5 Information for US emissions certification (EPA/CARB)
6 EU type approval
7 EU country of origin (Germany)
8 Year of construction (year/month)
9 Bar code (engine number)
The following data must always be specified in case of queries and for spare parts orders:
1 Model designation
2 Engine number
8
9

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Lubricating oil circuit
6 7 8
5 4
3 2 1
9
10
11 12
13
14
1 Oil intake pipe
2 Oil pressure relief valve
3 Oil pump
4 Oil cooler
5 Oil filter
6 Check valve
7 Camshaft
8 Oil pressure sensor
9 Roller tappet with HVA element
10 Push rod
11 Rocker arm bearing block with injection
nozzles
12 Turbocharger
13 Piston cooling
14 Crankshaft

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Cooling circuit
Cooling circuit diagram 4H50
Coolant pump intake
Coolant pump
Water pump pressure side
EGR manifold
Bypass
Radiator
Coolant expansion tank
EGR main
radiator Oil radiator
EGR pre-
radiator
Cabinheating
Crank case input manifold
Cylinder 1-4 ; Cylinder head 1-4
Crank case output manifold
Thermostat
EGR
Valve

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Cooling circuit
Cooling circuit diagram 4H50 – within the engine
Return coolant radiator
Return expansion tank
Water pump intake
Bypass thermostat Water pump
Water pump pressure side
Crank case Input manifold
Crank case output manifold
Air vent cylinder head

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Cooling circuit
Cooling circuit diagram 4H50 – radiator and cabin heating
Intake from crank case output manifold
Air vent
radiator
Return pipe cabin heating
Supply from radiator to water pump intake
Input radiator
Supply
cabin heating

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Cooling circuit
Cooling circuit diagram 4H50 – exhaust gas recirculation and oil radiator
Intake EGR manifold crankcase manifold
EGR Valve
EGR manifold
EGR pre-cooler
Return from EGR
to coolant manifold
EGR main cooler
Coolant manifold
Intake from EGR manifold
to oil radiator
Return from oil radiator
to coolant manifold
Oil radiator
Return from coolant manifold to water pump
Air vent
expansion tank

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Sealants and adhesives
Application of sealant and adhesive material:
502 230 01 Loctite Activator 500 ml
700 189 18 Loctite 243 50 ml
502 234 00 Loctite 648 10 ml
502 825 01 Silicon 30 ml
700 218 15 Silicon 300 ml
502 830 02 high-temperature paste 1000 g

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Special tools and workshop equipment
Assembly/disassembly cylinder head + exterior area
Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
626 383 00
612 099 00
620 307 01
612 090 01
700 217 64
700 106 34
700 106 76
653 368 00
653 474 00
700 113 94
702 534 99
702 534 97
702 534 98
Piston ring collet chuck ø 70 - 100mm
Multi-tooth wrench socket M8
Strap wrench
Piston ring expander
Socket wrench for cyl.K E14 1/2"
Socket wrench SW 27 for oil pressure sensor
Socket wrench SW 36 for oil filter adapter
Centering bolts for engine mount
Measurement device for gap
Hose clamping tongs
Kink torque wrench
Screwdriver torque
Rotation angle measurement device (Gedore)
Ident no.No.

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1
2
3
4
5
6
7
8
9
10
11
12
13

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Special tools and workshop equipment
Assembly/disassembly - engine
Designation
1
2
3
4
5
653 480 00
653 466 00
653 464 00
653 517 00
702 517 89
Counterholder for flywheel
Assembly pin for roller tappet
Magnet holder for roller tappet guide
Turning device for engine benches
Socket wrench for conrod T50 1/2"
Ident no.No.