Hatz Diesel 4H50TIC User manual

4H50TIC
www.HATZ- DIESEL.com
Hat z Di esel
CREATING POWER SOLUTIONS.
OPERATOR’ S MANUAL
Diesel engine
0000 436 004 00- 07.2014 - 0.1
Printed in Germany
EN
Motorenfabrik Hatz GmbH & Co. KG
Ernst-Hatz-Str. 16
94099 Ruhstorf a.d. Rott
Deu t s c hl an d
Tel. [phone]
Fax [phone]
market ing@hatz- diesel.de
www.hat z- di esel.c om
CREATI NG POWER SOLUTI ONS.
Table of contents
1 Notices ............................................................................................................. 5
2 General information ........................................................................................ 6
3 Safety ............................................................................................................... 7
3.1 General information .......................................................................................... 7
3.1.1 Intended use and foreseeable misuse .............................................................. 7
3.1.2 Machine user or machine manufacturer obligations ......................................... 8
3.1.3 Representation of safety notes ......................................................................... 9
3.1.4 Meaning of safety symbols ............................................................................... 10
3.2 Safety notes ...................................................................................................... 11
3.2.1 Operational safety ............................................................................................. 11
3.2.2 Machine-specific safety instructions for operation ............................................ 14
3.2.3 Machine-specific safety instructions for maintenance work .............................. 15
3.2.4 Electrical equipment .......................................................................................... 18
3.3 Labels ............................................................................................................... 19
4 Technical data ................................................................................................. 20
4.1 Engine information and filling quantities ........................................................... 20
4.2 Engine type plate .............................................................................................. 21
4.3 Engine oil .......................................................................................................... 22
4.4 Coolant .............................................................................................................. 23
4.5 Fuel ................................................................................................................... 26
5 Engine design ................................................................................................. 28
5.1 Overview ........................................................................................................... 28
6 Transport, assembly and commissioning .................................................... 31
6.1 Transport - Engine with 2 lifting eyes ................................................................ 31
6.2 Assembly instructions ....................................................................................... 32
6.3 Preparations for commissioning ........................................................................ 33
6.4 Filling engine oil ................................................................................................ 33
6.5 Filling the cooling system .................................................................................. 35
7 Operation and use .......................................................................................... 38
7.1 Safety notes ...................................................................................................... 38
7.2 Performing tests ................................................................................................ 38
7.3 Starting the engine ............................................................................................ 39
7.4 Starting the engine for the first time/after a filter change .................................. 42
7.5 Switching off the engine .................................................................................... 45
7.6 Checking the oil level and adding oil if necessary ............................................ 47
7.7 Refueling ........................................................................................................... 49
8 Maintenance .................................................................................................... 51
8.1 General maintenance instructions .................................................................... 51
8.2 Maintenance work ............................................................................................. 52
4H50TIC Table of contents
HATZ Operator's Manual 3

8.2.1 Maintenance plan .............................................................................................. 52
8.2.2 Checking the intake area of the combustion air ................................................ 54
8.2.3 Checking the radiator fins for dirt accumulation ................................................ 55
8.2.4 Checking the cooling system ............................................................................ 57
8.2.5 Changing the engine oil and oil filter ................................................................. 59
8.2.6 Cleaning the radiator fins .................................................................................. 64
8.2.7 Tensioning the poly v belt ................................................................................. 67
8.2.8 Replacing the poly v belts ................................................................................. 69
8.2.9 Changing the oil separator of the crankcase ventilation ................................... 71
8.2.10 Checking the screw connections ...................................................................... 72
8.2.11 Draining the water separator ............................................................................. 73
8.2.12 Changing the fuel prefilter ................................................................................. 74
8.2.13 Changing the fuel fine filter ............................................................................... 77
8.2.14 Servicing the air filter (optional) ........................................................................ 80
8.2.15 Changing coolant .............................................................................................. 82
9 Faults ............................................................................................................... 86
9.1 Fault table ......................................................................................................... 86
10 Storage and disposal ...................................................................................... 95
10.1 Storing the machine .......................................................................................... 95
10.2 Disposing of the machine .................................................................................. 95
11 Installation declaration ................................................................................... 97
Table of contents 4H50TIC
4 Operator's Manual HATZ
1Notices
Contact data
© 2014
Motorenfabrik HATZ
Ernst-Hatz-Straße 16
94099 Ruhstorf
Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.hatz-diesel.com
All rights reserved!
Copyright
The copyright for this Operator's Manual rests entirely with Motorenfabrik
HATZ, Ruhstorf.
This Operator's Manual may only be copied or distributed if written approval
has been received. This also applies to the copying or distribution of ex-
cerpts of the Operator's Manual. The same conditions apply to distribution of
the Operator's Manual to third parties in digital form.
Original Operator's Manual
This Operator's Manual was translated into multiple languages.
The German version is the original Operator's Manual. All other language
versions are translations of the original Operator's Manual.
4H50TIC Notices
HATZ Operator's Manual 5

2General information
Information on the document
This Operator's Manual was created with due care. It is exclusively intended
to offer a technical description of the machine and to provide instructions on
commissioning, operating and maintaining the machine. When operating the
machine, 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 the Operator's Manual carefully and keep it close
by for ready access.
Machine
This Operator's Manual describes the following machine.
Machine name HATZ diesel engine
Type number 4H50TIC
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the more than 500 HATZ service stations.Trained
specialists 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 serv-
ice station nearest you, please see the directory enclosed or visit the inter-
net at: www.hatz-diesel.com
Problems may occur if unsuitable spare parts are installed. We cannot ac-
cept responsibility for damage and secondary damage that result 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 responsible for personal injury, damage to
property, or damage to the machine itself caused by improper use, foreseea-
ble misuse, or failure to follow or adequately follow the safety measures and
procedures described in this Operator's Manual. This also applies to
changes made to the machine and use of unsuitable spare parts.
Modifications, which serve the technical improvements, are reserved.
General information 4H50TIC
6 Operator's Manual HATZ
3Safety
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 are followed.
Read this chapter carefully before beginning work.
3.1.1 Intended use and foreseeable misuse
Intended use
The machine described in this Operator's Manual fulfills the following func-
tions:
▪Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See chapter 11 Installation declaration,
page 97.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine into 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. Responsibility
is not accepted by Motorenfabrik HATZ for damage resulting from this situa-
tion.
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 in this Operator's 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.
▪Operation in flammable or hazardous environments.
▪Operation in closed-off or poorly ventilated rooms.
4H50TIC Safety
HATZ Operator's Manual 7

▪Installation of the machine in moving equipment (e.g. vehicles, trailers) or
in closed rooms without additional measures to handle supply air, extract
air, and exhaust gas.
▪Improper operation at variance with DIN 6271 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 14 and in chapter 3.2.3 Machine-
specific safety instructions for maintenance work, page 15 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 user is obligated to only operate the machine while it is in perfect condi-
tion. The user must check the condition of the machine before using it and
ensure that any defects are eliminated before it is taken into service. Run-
ning the machine while identified defects exist is not permitted. The user
must also ensure that the information contained in the Operator's Manual
has been read and understood.
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood the Operator's Manual or must possess the qualifica-
tions necessary for working with this equipment, acquired in training/instruc-
tional courses. No one may work with the machine without the necessary
qualifications, even if for just a brief period.
The operating personnel must not be under the influence of drugs, medica-
tion or alcohol.
All work performed on the machine must be in compliance with the informa-
tion provided in the Operator's Manual.
Safety 4H50TIC
8 Operator's Manual HATZ
Storing the Operator's Manual
This Operator's 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 ac-
cessible 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 related description or operating step.
Structure of the safety notes
The safety notes consist of:
▪Warning symbol
▪Signal word
▪Description of danger
▪Possible consequences
▪Preventative measures
General danger symbol
The general danger symbol is used to identify the danger of personal injury.
Signal words
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
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.
4H50TIC Safety
HATZ Operator's Manual 9

Danger symbol/
signal word
Meaning
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 referen-
ces.
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this Operator's Manual.
Symbol Meaning
Smoking, fire and open flames are prohibited.
Warning of personal injury!
Warning of hot surfaces!
Warning of flammable substances!
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
Safety 4H50TIC
10 Operator's Manual HATZ
Symbol Meaning
Warning of heavy loads!
Warning of environmental damage!
Comply with the Operator's Manual or additional documenta-
tion from other manufacturers or the user.
i
Additional information that is useful to the reader.
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 the Operator's Manual and
the safety instructions contained therein.
▪As the user of the machine, you must ensure that all people
working on the machine are familiar with the contents of this
Operator's Manual.
▪Before working on the machine, read this Operator's 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.
4H50TIC Safety
HATZ Operator's Manual 11

Using the machine
▪Only operate the machine for the purposes described in the chapter 3.1.1
Intended use and foreseeable misuse, page 7.
Compliance with other regulations
▪Adhere to the applicable accident prevention regulations of the trade asso-
ciations.
▪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 required
personal protective equipment is specified in the description of the operating
steps.
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,
spraying acid).
Working clothes Wear close-fitting clothing. How-
ever, it must not restrict the
wearer's freedom of movement.
Safety 4H50TIC
12 Operator's Manual HATZ
Warning labels and information signs on the machine
The warning labels and information signs on the machine must be followed
(see the 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 the chapter 2 General
information, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.
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 the Operator's Manual.
▪Heed the warnings on the machine and in the Operator's
Manual.
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪The personnel must have read and understood this Opera-
tor's Manual or must possess the qualifications necessary
for working with this equipment, acquired in training/instruc-
tional courses.
▪Only qualified personnel are permitted to operate and main-
tain this machine.
▪Failure to comply will cause the warranty to become void.
4H50TIC Safety
HATZ Operator's Manual 13

WARNING
Danger of injury from the failure to follow the operating in-
structions and from performing unauthorized tasks on the
machine.
▪Follow all instructions.
▪Do not perform activities for which no qualification is availa-
ble. 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 the chapter 6.1 Trans-
port - Engine with 2 lifting eyes, page 31).
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.
Safety 4H50TIC
14 Operator's Manual HATZ
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.
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪Only refuel when the engine is switched off.
▪Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪Do not smoke.
▪Do not spill fuel.
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.
4H50TIC Safety
HATZ Operator's Manual 15

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 more than 500 HATZ service stations.
Replacing parts
▪When replacing defective components, we recommend that you use gen-
uine HATZ original spare parts (see the 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 flam-
mable, can become electrostatically charged and can generate
an explosive gas-air mixture.
▪Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
DANGER
Fire hazard from spontaneous combustion.
Cleaning materials soaked with cold cleaner may produce heat
together with atmospheric oxygen and combust spontaneously.
▪Collect cleaning materials soaked with cold cleaner only in
fire-proof, tightly sealed containers.
▪Do not dispose of cold cleaner residues and used cleaning
materials with domestic waste, rather only in accordance
with manufacturer instructions.
▪Comply with the instructions for preventing fire on the safety
data sheet for the cold cleaner.
Safety 4H50TIC
16 Operator's Manual HATZ
WARNING
Danger of injury from compressed air and dust particles.
Eye injuries may occur when cleaning with compressed air.
▪Wear safety goggles.
CAUTION
Danger of injury if maintenance instructions are not fol-
lowed.
▪Only perform maintenance when the engine is switched off.
▪For engines with an electric starter:
Disconnect the negative battery terminal.
Protect the starting key against unauthorized access.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪Let the engine cool before maintenance.
4H50TIC Safety
HATZ Operator's Manual 17

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 on the battery.
▪Before performing work on the electrical equipment, always
disconnect the negative terminal of the battery.
▪Never swap the positive (+) and negative (–) battery termi-
nals.
▪When installing the battery, first connect the positive cable
and then the negative cable.
▪When removing the battery, first disconnect the negative
cable and then the positive cable.
▪It is imperative that you prevent short circuits and mass con-
tact 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.
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.
Safety 4H50TIC
18 Operator's Manual HATZ
NOTICE
▪The necessary wiring diagrams are included with the ma-
chine if it is equipped with electrical equipment. Additional
wiring diagrams can be requested when needed.
▪We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
▪Promptly replace faulty indicator lamps.
▪Do not pull out the starting key during operation.
▪Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪When cleaning, do no spray the electrical equipment components with a
water jet or high pressure cleaner.
▪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-in connection to the voltage regu-
lator.
3.3 Labels
Warning labels and information signs on the engine
Label Meaning
BIO
DIESEL
052 356 02
Refuel with diesel fuel only. For the
specification, see the chapter 4.5
Fuel, page 26
Do not use bio diesel.
0000 053 657 02
The engine may only be operated
with fuel that is "EXTREMELY LOW
IN SULFUR OR SULFUR-FREE".
The fuel label is located close to the
fuel cap. If there is no fuel tank in-
stalled on the engine, the label must
be applied permanently close to the
fuel filler opening.
4H50TIC Safety
HATZ Operator's Manual 19

4Technical data
4.1 Engine information and filling quantities
Type 4H50TIC
Type Liquid-cooled four stroke diesel engine
Combustion system Direct injection, turbocharger with charge air cool-
ing, cooled exhaust-gas recirculation
Injection system Bosch common rail
Number of cylinders 4
Bore/stroke mm 84 / 88
Displacement cm
3
1,952
Engine oil capacity Approx.
ltr.
7.0
1)
Difference between the
"max." and "min."
marks
Approx.
ltr.
1.0
1)
Engine oil consumption
(after running-in period) Max. 0.5 % of fuel consumption, pertaining to full load
Engine oil pressure 2.5 bar to 4.5 bar
Coolant quantity Approx.
ltr.
12.5 (HATZ standard radiator with external expan-
sion tank)
13.2 (HATZ OpenPowerUnit radiator with integrat-
ed expansion tank)
Sense of rotation When viewing flywheel: left
Tappet clearance Automatic valve lash adjustment with hydraulic
valve tappets
Max. perm. inclination
during continuous opera-
tion in every direction
30°
2)
(with HATZ standard radiator)
20°
2)
(with HATZ OpenPowerUnit radiator)
Weight (without operating
fluids)
Approx.
kg
226 (with HATZ standard radiator and catalytic
converter)
260 (with HATZ OpenPowerUnit radiator and cata-
lytic converter)
Battery capacity Max. 12 V – 110 Ah / 450 A according to DIN
24 V – 66 Ah / 300 A according to DIN
Technical data 4H50TIC
20 Operator's Manual HATZ
1)
These values are approximations only. The max. mark on the dipstick is
decisive in any case (see the chapter 7.6 Checking the oil level and adding
oil if necessary, page 47).
2)
Exceeding these limit values can cause engine damage.
4.2 Engine type plate
120R- xxxxxx* xx
24R- xxxxxx
EMISSIONCONTROLINFORMATION
MOTORENFABRIK HATZ KG¬D- 940 99 RUHSTORF
GMBH
+CO
Model: 4H50TIC162J
S/N: 1361014000001 Build: 03/ 2014
Power: 36.4kW@1800 RPM Constant
Displ: 1.95L
Eng.Fam: FHZXL1.95C50
Em i s s i o n Cont ro l Sy s t em : DDI , DOC, EGR, ECM, TC, CAC
Pow er Cat e go r y: 1 9 ≤kW<37
ULTRA LOW SULFUR DIESEL FUEL ONLY.
THI S ENGI NE COMPLI ES WI TH U. S. EPA AND CALI F ORNI A REGULATI ONS
FOR THE MY2 0 15 YEAR NONROAD DI ESEL ENGI NES.
Use in Const ant - Speed Applications only.
EU- Type: e1* 97/68KA* 2012/ 46* 0801* 00 (IIIA)
www.hat z- d iesel.c om
187_44_C_3B
120R xxxxxx* xx
24R
xxxxxx
E1
8
9
The engine type plate is located on the crankcase and contains the following
engine information:
1Model designation of the engine
2Engine serial number
3Serial rating (kW) at nominal speed (rpm)
4Displacement (liters)
5Information for US emission certification (EPA/CARB)
6EU type approval
7EU country of origin (Germany)
8Model year (month/year)
9Bar code (engine serial number)
The following data must always be specified for requests and spare part or-
ders
1Model designation
2Engine serial number
4H50TIC Technical data
HATZ Operator's Manual 21

4.3 Engine oil
Oil quality
All brand name oils that satisfy at least the following specification are suita-
ble:
Engines with catalytic converter or with catalytic converter and partic-
ulate filter
▪ACEA E6 " Low SAPS" (preferred)
▪ACEA E9
▪ACEA C3 / C4 (HTHS ≥3.5 mPas)
▪API CJ-4
CAUTION
Damage to the catalytic converter and/or particulate filter
from using unsuitable engine oil.
Unsuitable engine oil diminishes the functionality and service life
of the catalytic converter and/or particulate filter.
Only use engine oil that fulfills the specifications stipulated
above. In principle, engine oils with low ash (low SAPS) are rec-
ommended.
Engines without catalytic converter and without particulate filter
▪ACEA E6, E7 or E9
▪ACEA C1, C2, C3 or C4
▪API CJ-4 or CI-4
Oil viscosity
Technical data 4H50TIC
22 Operator's Manual HATZ
Select the recommended viscosity depending on the ambient temperature in
which the engine will be operated.
CAUTION
Engine damage from unsuitable engine oil.
Unsuitable engine oil considerably reduces engine service life.
Only use engine oil that fulfills the specifications stipulated
above.
4.4 Coolant
Introduction
Liquid-cooled engines require a coolant specified by HATZ for engine cool-
ing.
Coolant is prepared in accordance with manufacturer's instructions, please
comply with the information on the packaging label.
Radiator protection fluids give effective protection against corrosion and
freezing. Additionally, the coolant boiling point is significantly raised and de-
posits of lime in the cooling system are reduced.
Safety notes
CAUTION
Danger of damage to health
Radiator protection fluids are harmful to health.
▪Avoid contact to eyes and skin.
▪Store only in the sealed original container and in a place in-
accessible for unauthorized persons.
▪Comply with manufacturer's instructions.
CAUTION
Danger of environmental damage from spilled coolant.
Coolant is water-polluting.
▪Do no allow it to enter the ground water, water bodies, or
sewage system.
▪Collect coolant and dispose of it in an environmentally com-
patible manner.
4H50TIC Technical data
HATZ Operator's Manual 23

CAUTION
Danger of engine damage from radiator protection fluid.
Use of a radiator protection fluid not approved by HATZ may
cause engine damage.
▪If you have any questions, please contact your nearest
HATZ service station before commissioning the engine.
CAUTION
Danger of engine damage by mixing radiator protection flu-
ids from different manufacturers.
The effectiveness may be degraded when different radiator pro-
tection fluids are mixed. The consequence may be damage to
the water pump, radiator, hoses, and gaskets.
▪Before changing the product, flush the entire cooling system
(see the chapter 8.2.15 Changing coolant, page 82).
Approved radiator protection fluids
The following radiator protection fluids are approved by HATZ:
Manufacturer Product name
ARAL Aral Antifreeze Silikatfrei (silicate-free)
Arteco Havoline XLC (OF02), Havoline XLC+B
Auto-Teile-Ring Cartechnic Antifreeze CT 12 plus
BASF Glysantin® G30®, Glysantin® G40®
Belgin Madeni
Yaglar Tic
LUBEX ANTIFREEZE G-12 PLUS
BP BP Procool
Bucher MOTOREX COOLANT M4.0
BVG Blume Mofin Antifreeze M40 Extra
Castrol Radicool SF, Radicool Si OAT
CCI LLC C521, LLC L415
CHEMIA-
BOMAR
Glidex Extra Premium
Chevron Caltex Extended Life Coolant, Havoline XLC Concentrate,
Ursa ELC NF Concentrate
CLASSIC CLASSIC KOLDA UE G30, CLASSIC KOLDA UE G40
Technical data 4H50TIC
24 Operator's Manual HATZ
Manufacturer Product name
Eurolub Radiator protection fluid D-30, PROCAR radiator protec-
tion fluid silicate-free, radiator protection fluid D-40 SU-
PER
Exxon Mobil Delvac ELC Coolant
Fuchs MAINTAIN FRICOFIN G 12 PLUS, MAINTAIN FRICOFIN
LL, MAINTAIN FRICOFIN DP
Gazpromneft-
Lubricants
G-ENERGY ANTIFREEZE SNF
Krafft K-140 Energy - Plus
Kuttenkeuler Kuttenkeuler Antifreeze K 12 Plus
LUKOIL OMV coolant SF, OMV coolant SOT
Mitan Alpine C40, Alpine C12+
MOL-LUB EVOX Premium Concentrate
Müller Minera-
löle
Startol Top G 12 Plus
Neste Markki-
nointi
Neste Superjäähdytinneste XLC
OAO Techno-
form
Cool Stream Premium
Old World In-
dustries
Final Charge Global Coolant
Petrol Ofisi
Anonim Sirketi
PO EXTENDED LIFE coolant
Tedex Tedex Antifreeze OT LL
Total Total Glacelf Auto Supra
Valvoline Zerex G 30, Zerex G 40-91
NOTICE
i
Prior approval from HATZ is needed when none of these radia-
tor protection fluids is available or an own-product radiator pro-
tection fluid is to be used.
4H50TIC Technical data
HATZ Operator's Manual 25

Preparation of the coolant
CAUTION
Danger of engine damage from incorrect radiator protection
fluid concentration.
A too low radiator protection fluid concentration increases the
risk of corrosion and also the risk of the cooling system freezing.
A radiator protection fluid proportion of over 50 vol% degrades
the cooling action and also the protection against frost is re-
duced. Therefore, serious engine damage may result from ex-
ceeding or dropping below the radiator protection fluid concen-
tration.
▪The radiator protection fluid must be prepared according to manufacturer's
instructions before pouring it into the cooling circuit. Comply with the infor-
mation on the packaging label.
▪If the radiator protection fluid has to be mixed with water, use only clean
water that is not too hard. Tap water with as low as possible content of
salt, minerals, and suspended matter is ideal. Distilled water is equally ide-
al.
The coolant mixture ratio is not to be below or exceed the following concen-
tration:
Radiator protection
fluid
Water Frost-resistant to ap-
prox.
min. 40 vol% 60 vol% -27 °C
max. 50 vol% 50 vol% -38 °C
NOTICE
i
As the corrosion and antifreeze concentration reduces with time,
carry out an annual check with a commercially available anti-
freeze tester. If the concentration is too low, change the coolant
independent of the service interval (see the chapter 8.2.15
Changing coolant, page 82).
4.5 Fuel
Fuel type
All types of diesel fuel that meet the minimum requirements of the following
specifications are suitable:
▪Europe: EN 590
▪UK: BS2869 A1/A2
▪USA: ASTM D 975-09a 1-D or 2-D (engines without catalytic converter
and without particulate filter)
ASTM D 975-09a 1-D S15 or 2-D S15
Technical data 4H50TIC
26 Operator's Manual HATZ
▪Japan: JIS K 2204 (with a maximum HFRR value of 520 µm)
CAUTION
Danger of engine damage from low quality fuel.
The use of fuel that does not meet the specifications can lead to
engine damage.
▪Only use fuel that is very low in sulfur or that contains no
sulfur at all.
▪The use of fuel that does not meet specifications requires
approval by Motorenfabrik HATZ (main plant).
4H50TIC Technical data
HATZ Operator's Manual 27

5Engine design
5.1 Overview
Intake side
4
32
5
5
6
7
8
9
10
11
12
13
14
15
16
17
1
Engine design 4H50TIC
28 Operator's Manual HATZ
1Intake opening for combustion air
2Rain cap
3Air filter (optional)
4Dust discharge valve
5Lifting eyes
6Fan
7Oil filter
8Fuel fine filter
9Side oil drain screw
10 Starter (low mounting position)
11 Electric fuel pump
12 Drain plug on fuel prefilter
13 Fuel prefilter
14 Engine type plate
15 Dipstick
16 Oil filler plug, bottom
17 Crankcase ventilation
4H50TIC Engine design
HATZ Operator's Manual 29

Exhaust side
123
4
5
67
8
9
1Expansion tank for coolant
2Oil filler plug, top
3Turbocharger
4Oxidation catalytic converter
5Exhaust outlet
6Starter (high mounting position)
7Oil drain screw, front
8Poly v belt
9Cooler
Engine design 4H50TIC
30 Operator's Manual HATZ
6Transport, assembly and commissioning
6.1 Transport - Engine with 2 lifting eyes
Safety notes
WARNING
Danger of injury from improper lifting and transport.
Danger of crushing from falling or tipping of the engine.
▪Only use the lifting eye already mounted on the machine for
lifting.
▪Only use a suitable hoist with a sufficient carrying capacity.
▪Do not remain under suspended loads.
CAUTION
Only use lifting lugs for transporting the engine.
Do not use for lifting the entire machine.
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.
NOTICE
Danger of environmental damage from leaking fluid.
If the machine is tilted, engine oil and fuel can run out.
▪Only transport the machine in an upright position.
4H50TIC Transport, assembly and commissioning
HATZ Operator's Manual 31

Lifting points
1Lifting point
Transport conditions
▪Two lifting eyes (1) are used on engines with a HATZ standard radiator.
Ensure that the load on the lifting eyes is always vertical.
▪The lifting eyes deform when they are overloaded. If this happens, the lift-
ing eyes must be replaced and if necessary additional lifting points must
be used.
▪When transporting the machine, follow the safety instructions.
▪When transporting, follow the applicable safety and accident prevention
regulations of the trade associations.
▪After delivery, check the machine for completeness and transport damage.
▪Only transport the machine when it is switched off and has cooled down.
▪If you have questions on transporting the machine, please contact your
nearest HATZ service station. For contact data, see the chapter 1 Im-
pressum, page 5 or www.hatz-diesel.com.
6.2 Assembly instructions
Assembly notes
HATZ diesel engines are efficient, robust and long-lived. Therefore, they are
usually installed in machines that are used for commercial purposes.
The machine manufacturer must follow the applicable regulations regarding
machine safety – the engine is a part of a machine.
Depending on the use and installation of the engine, it may be necessary for
the machine manufacturer and machine user to install safety equipment to
prevent inappropriate use. Note the following:
Transport, assembly and commissioning 4H50TIC
32 Operator's Manual HATZ
▪Parts of the exhaust gas system and the engine surface become hot dur-
ing operation and should not be touched until they cool down after the en-
gine is switched off.
▪Incorrect cable connections and incorrect operation of the electrical equip-
ment can lead to sparking and must be avoided.
▪After the engine is installed in the machine, rotating parts must be protect-
ed against contact.
HATZ safety equipment is available for the belt drive of the cooling fan and
alternator.
▪Comply with all notice and warning labels on the engine and keep them in
a legible condition. If a label should become detached or be difficult to
read, it must be replaced promptly. For this purpose, contact your nearest
HATZ service station.
▪Any improper modification of the engine results in a loss of liability cover-
age for resulting damage.
Only regular maintenance, as specified in this Operator's Manual, will main-
tain the operating readiness of the engine.
The assembly instructions contain important information on how to safely as-
semble the engine. They are available from any Hatz service station.
If you have any questions, please contact your nearest HATZ service sta-
tion before commissioning the engine.
6.3 Preparations for commissioning
▪Check the delivered parts for completeness, damage, and other noticeable
issues.
▪Ensure that the setup location is adequately ventilated.
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪Never operate the machine in closed-off or poorly ventilated
rooms.
▪Do not breathe in the exhaust gases.
6.4 Filling engine oil
Engines are normally delivered without an engine oil filling.
4H50TIC Transport, assembly and commissioning
HATZ Operator's Manual 33

Safety note
CAUTION
Danger of later engine damage.
▪Operating the engine with an oil level below the min. mark
or above the max. mark can lead to engine damage.
▪When checking the oil level, the engine must be horizontal
and have been switched off for a few minutes.
Overview
1Dipstick
2Oil filler plug, top
3Oil refilling container
4Oil filler plug, bottom
Procedure
Step Activity
1Pull out the dipstick (1) and clean it.
Transport, assembly and commissioning 4H50TIC
34 Operator's Manual HATZ
Step Activity
2Depending on accessibility, unscrew oil filler plug (2) or (4).
3Fill engine oil. For the specification, viscosity and filling quantity,
see the chapter 4.3 Engine oil, page 22.
4Reinsert the dipstick.
5Pull out the dipstick and check the oil level.
6If required, top up engine oil to the max. mark.
7Reinsert the dipstick.
8Screw in the oil filler plug.
6.5 Filling the cooling system
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot cooling sys-
tem. The cooling system is pressurized.
▪Let the engine cool.
▪Wear safety gloves.
CAUTION
Danger of later engine damage.
▪Operating the engine with a coolant level below the MIN.
mark can lead to engine damage.
▪When checking the coolant level, the engine must be hori-
zontal and be switched off.
4H50TIC Transport, assembly and commissioning
HATZ Operator's Manual 35

Overview
MAX
MIN
MAX
MIN
12
43
1Expansion tank for coolant
2Sealing cap
3MAX - Maximum coolant level
4MIN - Minimum coolant level
Procedure
Step Activity
1Open the sealing cap (2).
2For the HATZ standard radiator: Top up coolant to the MAX
mark on the expansion tank.
For the HATZ OpenPowerUnit radiator: Top up coolant to the
edge of the pipe cut-out.
Preparation of the coolant, see the chapter 4.4 Coolant,
page 23.
3Tighten the sealing cap (2) by hand all the way.
4Start the engine (see the chapter 7 Operation and use,
page 38).
5Warm up the engine until the coolant has reached a tempera-
ture of approx. 85°C. Above this temperature the coolant is
pumped through the entire cooling system and forces out re-
maining air bubbles.
6Switch off the engine and let it cool down completely (see the
chapter 7 Operation and use, page 38).
7Check the coolant level again. The coolant must be seen be-
tween the MIN and MAX mark; for a warm engine the level can
also be slightly above the MAX mark.
Transport, assembly and commissioning 4H50TIC
36 Operator's Manual HATZ
Step Activity
8Check the cooling system for leaks, retighten the hose clips if
necessary (see the chapter 8.2.4 Checking the cooling system,
page 57).
4H50TIC Transport, assembly and commissioning
HATZ Operator's Manual 37

7Operation and use
7.1 Safety notes
NOTICE
Comply with the safety chapter!
Follow the basic safety instructions in the chapter 3 Safety,
page 7.
WARNING
Danger of injury from damage and defects on the machine.
▪Do not take the machine into service if damage has been lo-
calized and identified.
▪Replace faulty components.
WARNING
Danger of injury from the failure to follow the operating in-
structions and from performing unauthorized tasks on the
machine.
▪Define the responsibilities of the personnel taking the ma-
chine into service.
▪Replace faulty machine parts immediately.
▪Check the installation conditions when the machine is first
taken into service and after the machine has been inactive
for a lengthy period.
CAUTION
Danger of engine damage from low load operation.
Operating the engine at no load or at very low load for an ex-
tended period can impair the running characteristics of the en-
gine.
▪Make sure that the engine load is at least 15 %.
▪Before switching off the engine following low load operation,
briefly operate it at a considerably higher load.
7.2 Performing tests
Before starting
Before starting the engine, several tests need to be performed to ensure the
machine is working properly.
Operation and use 4H50TIC
38 Operator's Manual HATZ
Procedure
Step Test
1The machine is standing securely and on a level surface.
2The installation location is adequately ventilated.
3There is a sufficient amount of fuel in the fuel tank (see the chap-
ter 7.7 Refueling, page 49).
4There is a sufficient amount of engine oil in the engine housing
(see the chapter 7.6 Checking the oil level and adding oil if nec-
essary, page 47).
5There is a sufficient amount of coolant in the expansion tank
(see the chapter 8.2.4 Checking the cooling system, page 57).
6Radiator and radiator hoses are free from leaks (see the chapter
8.2.4 Checking the cooling system, page 57).
7No persons are located in the danger zone of the engine or ma-
chine.
8All safety equipment is in place.
7.3 Starting the engine
Safety notes
DANGER
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪Never operate the machine in closed-off or poorly ventilated
rooms.
▪Do not breathe in the exhaust gases.
CAUTION
Danger of engine damage from the use of starting fluid.
▪The use of engine damage from the use of starting fluid can
lead to uncontrolled ignition.
▪Engine damage from uncontrolled ignitions.
▪Never use starting fluid.
4H50TIC Operation and use
HATZ Operator's Manual 39

NOTICE
See also starting instructions in the documentation for the com-
plete machine.
Overview — HATZ instrument boxes
4
II
I
6
7
8
9
10
11
5
0
1
3
2
Pos. Designation
1Error diagnosis display
2Service interval indicator
3Button for error interrogation
4Protective cap
5Starting key
6Pre glow display
7Air filter service required
8Engine temperature display
9Oil pressure display
10 Charge control
11 Operating display
Ignition lock
0Off
IOperation
II Starting
Operation and use 4H50TIC
40 Operator's Manual HATZ
Procedure
NOTICE
i
▪After approx. 20 seconds the start procedure cuts off auto-
matically to protect the starter. If the engine is still not run-
ning after that, turn the starting key back to position "0" and
eliminate the cause (see the chapter 9.1 Fault table,
page 86).
▪Turn the starting key to position "0" every time you want to
start the engine.
▪The anti repeat device in the ignition lock makes it impossi-
ble for the starter to engage while the engine is running and
become damaged.
Step Activity
1Remove the protective cap (4) from the ignition lock.
2Insert the starting key all the way and turn to position "I".
Depending on the model, the following indicators light up:
▪Charge control (10)
▪Oil pressure display (9)
▪Pre glow display (6)
NOTE: If the optional engine temperature display (8) lights up,
the coolant temperature is impermissibly high. Do not start the
engine; eliminate the cause.
When the optional pre glow display (6) goes out, continue with
step 3.
3Turn the starting key to position "II".
4As soon as the engine is running, release the starting key.
▪The starting key springs back to position "I" and remains in
this position during operation.
▪The charge control (10) and oil pressure display (9) go out.
▪The operating display (11) lights up.
NOTICE
i
▪In case of irregularities, switch off the engine immediately.
▪Identify the fault and eliminate it.
▪For details of troubleshooting, see the chapter 9.1 Fault ta-
ble, page 86.
4H50TIC Operation and use
HATZ Operator's Manual 41