Motorenfabrik Hatz GmbH & Co. KG Ernst-Hatz-Str. 16 94099 Ruhstorf a.d. Rott Deutschland Tel. +49 8531 319-0 Fax +49 8531 319-418 marketing@hatz-diesel.de www.hatz-diesel.com CREATING POWER SOLUTIONS. 4H50TIC OPERATOR’S MANUAL Diesel engine 0000 436 004 00 - 07.2014 - 0.1 Printed in Germany EN Hatz Diesel CREATING POWER SOLUTIONS. www.HATZ-DIESEL.
4H50TIC Table of contents Table of contents 1 Notices ............................................................................................................. 5 2 General information ........................................................................................ 6 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 Safety ............................................................................................................... General information .......................
Table of contents 4H50TIC 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.2.12 8.2.13 8.2.14 8.2.15 Maintenance plan .............................................................................................. Checking the intake area of the combustion air ................................................ Checking the radiator fins for dirt accumulation ................................................ Checking the cooling system .....................................................
H50TIC 1 Notices Notices Contact data © 2014 Motorenfabrik HATZ Ernst-Hatz-Straße 16 94099 Ruhstorf Germany Tel. +49 (0)8531 319-0 Fax +49 (0)8531 319-418 marketing@hatz-diesel.de 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 excerpts of the Operator's Manual.
General information 2 4H50TIC General 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 inhouse regulations apply.
4H50TIC Safety 3 Safety 3.1 General information Introduction This chapter contains the information you need to work safely with this machine. 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.
Safety 4H50TIC ▪ 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.
4H50TIC Safety 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 accessible 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 technology and the recognized safety standards. Despite these precautions, risks exist when operating the machine and during maintenance work.
Safety 4H50TIC 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 information, such as operating tips and cross references. 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.
4H50TIC Safety Symbol Meaning Warning of heavy loads! Warning of environmental damage! Comply with the Operator's Manual or additional documentation from other manufacturers or the user. Additional information that is useful to the reader. i 3.2 Safety notes 3.2.1 Operational safety Introduction This chapter contains all of the important safety instructions for personal protection and for safe and reliable operation.
Safety 4H50TIC 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 associations. ▪ Comply with the regulations concerning the minimum safety and health requirements for the use of work equipment by workers at work.
4H50TIC Safety 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.
Safety 4H50TIC WARNING Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the machine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is available. 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 location can lead to injuries (of the back, for example).
4H50TIC Safety 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 4H50TIC 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 genuine HATZ original spare parts (see the chapter 2 General information, page 6).
4H50TIC Safety 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 followed. ▪ 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.
Safety 4H50TIC 3.2.4 Electrical equipment Safety notes DANGER Danger to life, danger of injury or danger of property damage 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 terminals. ▪ When installing the battery, first connect the positive cable and then the negative cable.
4H50TIC Safety NOTICE ▪ The necessary wiring diagrams are included with the machine 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.
Technical data 4H50TIC 4 Technical 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 cooling, cooled exhaust-gas recirculation Injection system Bosch common rail Number of cylinders 4 Bore/stroke mm 84 / 88 Displacement cm 1,952 Approx. ltr. 7.0 1) Difference between the "max." and "min." marks Approx. ltr. 1.
4H50TIC Technical data 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). 1) 2) 4.2 Exceeding these limit values can cause engine damage. Engine type plate EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ GMBH +CO KG ¬ D-94099 RUHSTORF 8 www.hatz-diesel.com Model: 4H50TIC – 162J S/N: 1361014000001 Build: 03/2014 Power: 36.4kW @ 1800 RPM Constant Displ: 1.95L Eng.Fam: FHZXL1.
Technical data 4.3 4H50TIC Engine oil Oil quality All brand name oils that satisfy at least the following specification are suitable: Engines with catalytic converter or with catalytic converter and particulate 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.
4H50TIC Technical data 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 cooling.
Technical data 4H50TIC 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 fluids from different manufacturers. The effectiveness may be degraded when different radiator protection fluids are mixed.
4H50TIC Technical data Manufacturer Product name Eurolub Radiator protection fluid D-30, PROCAR radiator protection fluid silicate-free, radiator protection fluid D-40 SUPER Exxon Mobil Delvac ELC Coolant Fuchs MAINTAIN FRICOFIN G 12 PLUS, MAINTAIN FRICOFIN LL, MAINTAIN FRICOFIN DP GazpromneftLubricants 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
Technical data 4H50TIC 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 reduced.
4H50TIC Technical data ▪ 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. HATZ ▪ 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).
Engine design 4H50TIC 5 Engine design 5.
4H50TIC HATZ Engine design 1 Intake opening for combustion air 2 Rain cap 3 Air filter (optional) 4 Dust discharge valve 5 Lifting eyes 6 Fan 7 Oil filter 8 Fuel fine filter 9 Side 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 Operator's Manual 29
Engine design 4H50TIC Exhaust side 1 9 30 3 2 8 7 1 Expansion tank for coolant 2 Oil filler plug, top 3 Turbocharger 4 Oxidation catalytic converter 5 Exhaust outlet 6 Starter (high mounting position) 7 Oil drain screw, front 8 Poly v belt 9 Cooler Operator's Manual 6 5 4 HATZ
4H50TIC Transport, assembly and commissioning 6 Transport, 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.
Transport, assembly and commissioning 4H50TIC Lifting points 1 Lifting 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 lifting eyes must be replaced and if necessary additional lifting points must be used. ▪ When transporting the machine, follow the safety instructions.
4H50TIC Transport, assembly and commissioning ▪ Parts of the exhaust gas system and the engine surface become hot during operation and should not be touched until they cool down after the engine is switched off. ▪ Incorrect cable connections and incorrect operation of the electrical equipment can lead to sparking and must be avoided. ▪ After the engine is installed in the machine, rotating parts must be protected against contact.
Transport, assembly and commissioning 4H50TIC 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 1 Dipstick 2 Oil filler plug, top 3 Oil refilling container 4 Oil filler plug, bottom Procedure 34 Step Activity 1 Pull out the dipstick (1) and clean it.
4H50TIC 6.5 Transport, assembly and commissioning Step Activity 2 Depending on accessibility, unscrew oil filler plug (2) or (4). 3 Fill engine oil. For the specification, viscosity and filling quantity, see the chapter 4.3 Engine oil, page 22. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level. 6 If required, top up engine oil to the max. mark. 7 Reinsert the dipstick. 8 Screw in the oil filler plug. Filling the cooling system Safety notes CAUTION Danger of burns.
Transport, assembly and commissioning 4H50TIC Overview 2 1 MAX MIN MAX MIN 3 1 Expansion tank for coolant 2 Sealing cap 3 MAX - Maximum coolant level 4 MIN - Minimum coolant level 4 Procedure 36 Step Activity 1 Open the sealing cap (2). 2 For 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.
4H50TIC HATZ Transport, assembly and commissioning Step Activity 8 Check the cooling system for leaks, retighten the hose clips if necessary (see the chapter 8.2.4 Checking the cooling system, page 57).
Operation and use 4H50TIC 7 Operation 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 localized and identified. ▪ Replace faulty components. WARNING Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the machine.
4H50TIC Operation and use Procedure 7.3 Step Test 1 The machine is standing securely and on a level surface. 2 The installation location is adequately ventilated. 3 There is a sufficient amount of fuel in the fuel tank (see the chapter 7.7 Refueling, page 49). 4 There is a sufficient amount of engine oil in the engine housing (see the chapter 7.6 Checking the oil level and adding oil if necessary, page 47). 5 There is a sufficient amount of coolant in the expansion tank (see the chapter 8.2.
Operation and use 4H50TIC NOTICE See also starting instructions in the documentation for the complete machine. Overview — HATZ instrument boxes 1 11 2 10 3 0 I 9 8 II 7 6 5 4 Pos.
4H50TIC Operation and use Procedure NOTICE i ▪ After approx. 20 seconds the start procedure cuts off automatically to protect the starter. If the engine is still not running 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.
Operation and use 7.4 4H50TIC Starting the engine for the first time/after a filter change 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.
4H50TIC Operation and use Pos. Designation 1 Error diagnosis display 2 Service interval indicator 3 Button for error interrogation 4 Protective cap 5 Starting key 6 Pre glow display 7 Air filter service required 8 Engine temperature display 9 Oil pressure display 10 Charge control 11 Operating display Ignition lock 0 Off I Operation II Starting Procedure NOTICE i HATZ ▪ After approx. 20 seconds the start procedure cuts off automatically to protect the starter.
Operation and use 4H50TIC Step Activity 2 Insert 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.
4H50TIC 7.5 Operation and use Switching off the engine Safety notes CAUTION Danger of injury from unauthorized access. There is a danger of injury if unauthorized persons handle the machine. ▪ Protect the starting key against unauthorized access during breaks in operation or after completing work. CAUTION Protect the ignition lock against dirt and moisture. ▪ With the starting key pulled out, seal the ignition lock with the protective cap. NOTICE Danger of overheating and full battery discharge.
Operation and use 4H50TIC Overview — HATZ instrument boxes 0 I 1 2 Pos. Designation 1 Starting key 2 Protective cap 2 Ignition lock 0 Off I Operation Procedure Step Activity 1 Turn the starting key (1) to position "0". The engine switches off. All indicator lamps go out. 46 2 Remove the starting key. 3 Seal the ignition lock with the protective cap (2).
4H50TIC 7.6 Operation and use Checking the oil level and adding oil if necessary Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Wear safety gloves. CAUTION Danger of later engine damage. HATZ ▪ 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.
Operation and use 4H50TIC Overview 1 Dipstick 2 Oil filler plug, top 3 Oil refilling container 4 Oil filler plug, bottom Procedure — Checking oil level/adding oil 48 Step Activity 1 Switch off the engine and wait several minutes for the engine oil to collect in the crank housing. Engine must be level. 2 Remove contamination on the engine in the area of the dipstick (1). 3 Pull out the dipstick and clean it. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level.
4H50TIC 7.7 Operation and use Step Activity 6 If the oil level is close to the min. mark, add engine oil to the max. mark. For the specification and viscosity, see the chapter 4.3 Engine oil, page 22. 7 Reinsert the dipstick. Refueling This diesel engine is intended for installation in a machine or for assembly with other machines to form a machine and does not have its own fuel tank. Follow the instructions from the manufacturer and comply with the following safety information.
Operation and use 4H50TIC CAUTION Engine damage from using low quality fuel. The use of fuel that does not meet the specifications can lead to engine damage. 50 ▪ Only use the fuel specified in the chapter 4.5 Fuel, page 26. ▪ The use of fuel that does not meet specifications requires approval by Motorenfabrik HATZ (main plant).
4H50TIC Maintenance 8 Maintenance 8.1 General maintenance instructions Safety notes WARNING Danger of injury from the failure to follow the operating instructions and from performing unauthorized tasks on the machine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is available. Contact properly trained personnel if necessary. NOTICE Comply with the safety chapter! Follow the basic safety instructions in the chapter 3 Safety, page 7.
Maintenance 4H50TIC ▪ Before starting, ensure that no persons are located in the danger zone of the engine or machine. Performance of maintenance work The entire machine is designed to be maintenance friendly. Parts that require maintenance are easily accessible. ▪ Perform maintenance work faithfully at the specified intervals to prevent premature wear of the machine. ▪ Follow the notice and warning labels on the machine. ▪ Always retighten screw connections loosened during maintenance work.
4H50TIC Symbol 500h Maintenance Maintenance interval Maintenance activity/Check Chapter Check the radiator fins for dirt accumulation. 8.2.3 Checking the radiator fins for dirt accumulation, page 55 Checking the cooling system 8.2.4 Checking the cooling system, page 57 Every 500 operat- Change the engine oil and oil ing hours or every filter1) 2 years Change the fuel prefilter1) 8.2.12 Changing the fuel prefilter, page 74 Change the fuel fine filter1) 8.2.
Maintenance 4H50TIC Symbol Maintenance interval Maintenance activity/Check If necessary, every 3000 operating hours at the latest Replacing the poly v belts Chapter 8.2.8 Replacing the poly v belts, page 69 Every 4000 oper- Clean the entire EGR section ating hours (EGR precooler, EGR valve, EGR main cooler as well as EGR mixing nozzle) (To be carried out by a trained specialist) Service according to service interval or after 2 years depending on which criteria is first.
4H50TIC Maintenance Overview (HATZ air filter) 1 Intake opening for combustion air 2 Dust discharge valve Procedure Step Activity 1 Check the intake opening (1) for coarse contamination such as leaves, heavy dust deposits, etc., and clean if necessary. 2 Check that the dust discharge valve (2) is clear. Remove dust seals by pressing them together. 8.2.3 Checking the radiator fins for dirt accumulation Safety notes CAUTION Danger of burns.
Maintenance 4H50TIC CAUTION Danger of injury. When working with compressed air, foreign bodies may fly into your eyes. ▪ Wear safety goggles. ▪ Never direct the compressed air jet toward people or toward yourself. CAUTION Danger of engine damage from overheating. The engine temperature display (option) lights up as soon as the engine becomes impermissibly hot. ▪ Switch off the engine immediately and eliminate the cause.
4H50TIC Maintenance Procedure Step Activity 1 Check the radiator fins (1) for coarse contamination such as leaves, heavy dust deposits, etc., and clean if necessary (see the chapter 8.2.6 Cleaning the radiator fins, page 64). 8.2.4 Checking the cooling system Safety notes CAUTION Danger of scalding and risk of environmental damage due to hot coolant. ▪ Excessive coolant is blown off from the sealing cap on the expansion tank.
Maintenance 4H50TIC 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 horizontal and be switched off.
4H50TIC Maintenance Checking the cooling system for leaks Coolants losses are mostly caused by leaks in the cooling system. On a non-leaking cooling system, losses only occur when the coolant boils and this then causes coolant to be pressed out of the cooling system at the sealing cap on the expansion tank. The cause of this can be contamination in the area of the radiator fins (see the chapter 8.2.3 Checking the radiator fins for dirt accumulation, page 55).
Maintenance 4H50TIC CAUTION Danger of environmental damage from spilled used oil. Used oil is water-polluting. ▪ Do no allow it to enter the ground water, water bodies, or sewage system. ▪ Collect the used oil and dispose of it according to local environmental regulations. 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.
4H50TIC Maintenance Procedure Step Activity 1 Depending on accessibility, the engine oil can be drained at oil drain screw (1) or (2). Unscrew the oil drain screw and drain the used oil entirely. 2 Screw in the cleaned oil drain screw with the new gasket (3) and tighten. Overview of changing the oil filter (horizontal installation) 1 Oil filter 2 Sealing surface 3 Gasket Procedure HATZ Step Activity 1 Loosen the oil filter (1) with a strap wrench or similar and unscrew it.
Maintenance 4H50TIC Overview of changing the oil filter (vertical installation) 1 Oil filter 2 Collar on the oil filter 3 Shaped element 4 Sealing surface 5 Gasket 6 Guard ring Procedure 62 Step Activity 1 Loosen the oil filter (1) with a strap wrench or similar and unscrew it until the collar (2) of the oil filter is at the same level as the shaped element (3). In this position, a valve releases the oil return into the crankcase which allows the oil filter to empty.
4H50TIC Maintenance Step Activity 3 Dispose of the old filter in accordance with local environmental regulations. 4 Thoroughly clean the shaped element (3) and sealing surface (4). 5 Lightly oil the sealing lip (5) of the new oil filter. 6 Screw in the oil filter and tighten it by hand. 7 Make sure that the guard ring (6) seats fully on the shaped element (3). The guard ring prevents dirt from accumulating between the oil filter and shaped element.
Maintenance 4H50TIC Procedure Step Activity 1 Pull out the dipstick (1) and clean it. 2 Depending on accessibility, unscrew oil filler plug (2) or (4). 3 Fill engine oil. For the specification, viscosity and filling quantity, see the chapter 4.3 Engine oil, page 22. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level. 6 If required, top up engine oil to the max. mark. 7 Reinsert the dipstick. 8 Screw in the oil filler plug.
4H50TIC Maintenance 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.
Maintenance 4H50TIC CAUTION Damage to the radiator fins through improper cleaning. ▪ Never spray the radiator fins with a high pressure jet. ▪ Never clean the radiator fins with a tool such as a spatula or screwdriver. A reduction in radiator performance through bent radiator fins or radiator leaks may be the result. NOTICE i In case of heavy contamination, shorten the maintenance intervals accordingly (see the chapter 8.2.1 Maintenance plan, page 52).
4H50TIC Maintenance Step Activity 1 Spray the entire area with a suitable cold cleaner according to the manufacturer's instructions and then clean off with a water jet. Work first against the direction of flow of the cooling air and then in the direction of flow. 2 Identify the cause of the oiling and seal the leak. 8.2.7 Tensioning the poly v belt Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance.
Maintenance 4H50TIC Overview 2 1 3 4 5 7 6 1 Alternator mounting bolt 2 Bracket 3 Belt tensioner 4 Hex nut 5 Clamping claw 6 Torque wrench with dial gage display 7 Measurement point for frequency measurement Procedure 68 Step Activity 1 Check the poly v belt for wear. Do not retension a worn poly v belt, but immediately replace it.
4H50TIC Maintenance Step Activity 2 Loosen the alternator mounting bolt (1) one or two revolutions. 3 Position the belt tensioner (3) with the guiding groove on the bracket (2). 4 Feed in the hexagon nut (4) of the mounting bolt into the clamping claw (5). Move the belt tensioner for this. 5 Adjusting the belt tension with a torque wrench: Place the torque wrench (with dial gage) on the belt tensioner, lay the counter support on the alternator housing.
Maintenance 4H50TIC Overview 1 5 2 6 3 4 1 Connecting screws, protective guard halves (top and bottom) 2 Fixing screw, protective guard (top and bottom) 3 Protective guard (left half) 4 Alternator mounting bolt 5 Poly v belt 6 Fan blade Procedure 70 Step Activity 1 Disassemble the left half of the protective guard (3) by unscrewing the screws (1) and (2) (at the top and bottom). 2 Loosen the alternator mounting bolt (4) one or two revolutions.
4H50TIC Maintenance 8.2.9 Changing the oil separator of the crankcase ventilation Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. Overview 4 1 Mounting bolts (captive) 2 Breather cap 3 Oil separator cartridge 4 Vent hose Procedure HATZ Step Activity 1 Release the four mounting bolts (1) on the breather cap (2). 2 Carefully lift the breather cap. If necessary, release the vent hose (4).
Maintenance 4H50TIC 8.2.10 Checking the screw connections Safety note NOTICE i ▪ Only retighten loose screw connections. Screw connections can be secured with thread locking adhesive or tightened to a defined torque. Retightening tight screw connections can cause damage. ▪ The adjustment screws on the injection system are secured with locking varnish and are not permitted to be tightened or adjusted. ▪ Do not retighten the screws for attaching the cylinder head.
4H50TIC Maintenance 8.2.11 Draining the water separator Safety note CAUTION Danger of environmental damage from spilled fuel. When water is drained from the water separator, a small amount of fuel is drained as well. ▪ Catch the emerging water-fuel mixture and dispose of it in an environmentally compatible manner. The fuel prefilter has a water separator. An electronic water level sensor signals when the maximum permissible water level is reached in the water separator.
Maintenance 4H50TIC Step Activity 2 Open the drain screw (2) and drain the water into the container. 3 If not enough liquid escapes, undo additional bleed screw (1). NOTE: If the fuel tank lies lower than the fuel prefilter, the fuel feed line must be clamped off with a hose clip (5). Otherwise fuel runs back into the fuel tank after the drain plug has been unscrewed. 4 As soon as fuel escapes, close the drain plug (2) and bleed screw (1). NOTE: First water escapes then fuel.
4H50TIC Maintenance CAUTION Danger of injury Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. CAUTION Danger of environmental damage from spilled fuel. When the filter is removed, a small amount of fuel is drained as well. ▪ Collect emerging fuel and dispose of it in an environmentally compatible manner. CAUTION Dirt particles can damage the injection system. ▪ Maintain clean conditions to ensure that dirt does not enter the fuel line.
Maintenance 4H50TIC 4 Water level sensor cable Procedure 76 Step Activity 1 Block the fuel feed line (1) between the fuel tank and fuel prefilter. 2 Place a suitable container under the filter to collect emerging fuel. 3 Disconnect the water level sensor cable (4) from the drain plug (3). 4 Release the drain screw (3) and drain the fuel. 5 Unscrew the fuel prefilter, fully unscrew the drain plug with integrated water level sensor.
4H50TIC Maintenance 8.2.13 Changing the fuel fine filter Safety notes DANGER Fire hazard from fuel Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Do not spill fuel. ▪ No open flames when working on the fuel system. ▪ Do not smoke. WARNING Danger of injury from fuel escaping under pressure. Large quantities of fuel under high pressure may escape when changing the fuel fine filter. ▪ Never open the bleed screw on the fuel fine filter.
Maintenance 4H50TIC CAUTION Danger of injury Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. CAUTION Danger of environmental damage from spilled fuel. When the filter is removed, a small amount of fuel is drained as well. ▪ Collect emerging fuel and dispose of it in an environmentally compatible manner. CAUTION Dirt particles can damage the injection system. ▪ Maintain clean conditions to ensure that dirt does not enter the fuel line.
4H50TIC Maintenance 1 Bleed screw (not open!) 2 Fuel feed line 3 Fuel fine filter 4 Hose clip 5 Strap wrench Procedure HATZ Step Activity 1 Block the fuel feed line (2) using the hose clip (4). 2 Place a suitable container under the filter to collect emerging fuel. 3 Unscrew the fuel fine filter (3) and according to local environmental regulations. 4 Lightly oil the gasket of the new fuel fine filter, fit the filter and tighten it by hand. 5 Release the fuel feed line.
Maintenance 4H50TIC 8.2.14 Servicing the air filter (optional) Safety notes CAUTION Danger of injury. When working with compressed air, foreign bodies may fly into your eyes. ▪ Wear safety goggles. ▪ Never direct the compressed air jet toward people or toward yourself. NOTICE i ▪ Change the filter elements when there is oily or damp dirt contamination, cleaning is not possible. ▪ Even minor damage in the areas of the sealing surface, filter paper, or filter cartridge makes reuse impossible.
4H50TIC Maintenance 7 9 8 9 1 Air filter housing 2 Retaining clips 3 Air filter cover 4 Dust discharge valve 5 Secondary filter 6 Primary filter 7 Air gun with extension tube (tip bent) 8 Lamp 9 Sealing surfaces Replacing the primary/secondary filters HATZ Step Activity 1 Open the retaining clips (2) and remove the air filter cover (3). 2 Pull out the primary filter (6) and either replace (recommended) or clean (see below).
Maintenance 4H50TIC Step Activity 6 Place the air filter cover on the air filter housing and lock all retaining clips making sure that the dust discharge valve points vertically downwards. Cleaning the primary filter Step Activity 1 Blow out the primary filter (6) with dry compressed air from the inside to the outside until dust no longer emerges. Use an air gun with an extension tube (7) with the end bent by approx. 90°. The end of the extension tube must not touch the filter paper.
4H50TIC Maintenance 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 compatible manner.
Maintenance 4H50TIC 10 1 Expansion tank for coolant 2 Sealing cap 3 MAX - Maximum coolant level 4 MIN - Minimum coolant level 5 Drain plug on the radiator 6 Gasket 7 Oil cooler 8 Hose clamp 9 Bottom coolant hose 10 Connector on the oil cooler Procedure 84 Step Activity 1 Position a suitable container to collect the used coolant (approx. 12.5 liters for the Hatz standard radiator or 13.2 liters for the HATZ OpenPowerUnit radiator).
4H50TIC HATZ Maintenance Step Activity 8 Filling the cooling system (see the chapter 6.5 Filling the cooling system, page 35).
Faults 4H50TIC 9 Faults 9.1 Fault table General troubleshooting notes If the cases listed below have been worked through but the fault continues to persist, please contact your nearest Hatz service station. Type of fault Possible causes Remedy Chapter The engine does not start or does not start immediately, but it can be turned with the starter. No fuel at the high pressure pump. Refuel. 7.7 Refueling, page 49 Systematically check the entire fuel supply. 8.2.
4H50TIC Faults Type of fault Possible causes Remedy Fuel gelled due to Check whether the insufficient cold re- fuel that emerges sistance. from the fuel feed line directly in front of the high pressure pump is clear and not cloudy. If the fuel has gelled, either warm the engine or drain the entire fuel supply system. Fill with a temperature-resistance fuel mixture. Oil is too viscous causing a too low starter speed. Change the engine oil and add oil of the right viscosity class. Chapter 4.
Faults 4H50TIC Type of fault Possible causes Remedy Chapter The starter does not switch on and the engine does not turn. Irregularities in the electrical equipment: Check the electrical equipment and their components. ▪ Battery and/or other cable connections are incorrectly connected. Contact Hatz service. 3.2.4 Electrical equipment, page 18 ▪ Cable connections are loose and/or oxidized. ▪ Ground connection between the chassis and engine is corroded. ▪ Battery is faulty and/or not loaded.
4H50TIC Faults Type of fault Possible causes Remedy Stop signal from monitoring elements that are associated with the automatic switchoff (optional): ▪ Check the oil lev- 7.6 Checkel. ing the oil level and ▪ Check the degree of dirt con- adding oil if tamination of the necessary, page 47 air filter, and ▪ No oil pressure. ▪ Dirty air filter unit. clean or renew it if necessary. ▪ ▪ Fuel pressure too low. ▪ Coolant level too low. ▪ Excess coolant temperature. ▪ Excess charge air temperature.
Faults 4H50TIC Type of fault Possible causes Remedy Chapter Poly v belt torn. Renew the poly v belt. 8.2.8 Replacing the poly v belts, page 69 Mechanical faults. Contact Hatz service. Engine switches off Stop signal of mon- ▪ Check the oil levby the automatic itoring elements el. electrical switch-off. for: ▪ Check the de▪ Oil pressure too gree of dirt conlow. tamination of the air filter, and ▪ Dirty air filter clean or renew it unit. if necessary. ▪ Fuel pressure ▪ Check the fuel too low.
4H50TIC Faults Type of fault Possible causes Remedy Irregularities in the electrical equipment, such as: Check the electrical equipment and its components, contact Hatz serv▪ Loose contacts on cable connec- ice if necessary. tions. Chapter 3.2.4 Electrical equipment, page 18 ▪ Faulty three phase alternator. ▪ Faulty relay. The engine loses power and speed. Engine runs due to an error in the emergency program. The fuel supply is impaired Switch off the engine, wait for a min.
Faults 4H50TIC Type of fault Possible causes Remedy Engine becomes very hot. Too much engine oil in the engine. Drain the engine oil 7.6 Checkto the max mark on ing the oil the dipstick. level and adding oil if necessary, page 47 Indicator light for excess coolant temperature lights up. Chapter Inadequate cooling: ▪ Clean the cooling 8.2.6 Cleanair area. ing the radi▪ Contamination in ▪ Clean the radia- ator fins, page 64 the entire area of tor fins, ensure 8.2.
4H50TIC HATZ Faults Flash signal Short – Long Possible causes 1–3 Area affected: Air supply ▪ Air filter is dirty. Remedy Chapter ▪ Service the air filter ▪ Charge air after charge air cooler ▪ Clean the radiatoo high. tor fins. 8.2.14 Servicing the air filter (optional), page 80 ▪ Charge air sensor/intake low pressure sensor cabling faulty. ▪ Check the cabling. 8.2.6 Cleaning the radiator fins, page 64 1–4 Area affected: Exhaust gas recirculation ▪ EGR sensor cabling faulty.
Faults 4H50TIC Flash signal Short – Long Possible causes Remedy 2–3 ▪ Engine oil pres- ▪ Check the oil levArea affected: sure too high/too el, top up engine Engine oil temperalow. oil if required. ture/engine oil ▪ Engine oil tem▪ Use engine oil pressure perature too with a suitable high. viscosity. ▪ Sensor cabling faulty. ▪ Check the water hoses for the oil cooler (hose kinked). Chapter 7.6 Checking the oil level and adding oil if necessary, page 47 4.
4H50TIC Storage and disposal 10 Storage and disposal 10.1 Storing the machine NOTICE Comply with the safety chapter! Follow the basic safety instructions in the chapter 3 Sicherheit, page 7. In addition, follow all safety instructions in the manufacturer documentation (see the list of documentation in the Appendix).
Storage and disposal 4H50TIC NOTICE When the machine has reached the end of its lifecycle, ensure that it is disposed of safely and properly, especially parts and substances that can be dangerous to the environment. These also include fuel, coolant, lubricants, plastics, and batteries (if present). 96 ▪ Do not dispose of the battery with the household trash. ▪ Dispose of the battery at a collection point for possible recycling.
4H50TIC 11 HATZ Installation declaration Installation declaration Operator's Manual 97
