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Hatz Diesel 4 H50 TIC Workshop Manual
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Hatz Diesel 4 H50 TIC Workshop Manual

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Workshop Manual
4 H 50 TIC
439 002 00 - 07.2015e Printed in Germany

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Summary of Contents for Hatz Diesel 4 H50 TIC

  • Page 1 Workshop Manual 4 H 50 TIC 439 002 00 - 07.2015e Printed in Germany...

  • Page 3: Table Of Contents

    Contents Preface 1. General 2. Additional equipment Engine illustrations Z 01 Main fuel filter Technical data Z 02 Suction hose Type plate details Z 03 Oxidation catalytic converter Lubricating oil circuit Z 05 Alternator Cooling circuit Z 05 Starter Sealants and adhesives Z 06 Engine base Special tools and workshop equipment Z 07 Oil cooler...
  • Page 4 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...

  • Page 5: Preface

    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.
  • Page 6 3 - 4H50 / 07.2015...

  • Page 7: General

    1. General 3 - 4H50 / 07.2015...
  • Page 8 Engine description Intake side 1 Intake opening for combustion air 10 Starter (low installation position) 2 Rain cap 11 Electric fuel pump 3 Air filter (option) 12 Fuel pre-filter 4 Dust discharge valve 13 Drain screw on the 5 Lifting eyes fuel pre-filter 6 Fan 14 Engine type plate...
  • Page 9 Engine description Exhaust side 1 Expansion tank for coolant 6 Starter (high installation position) (option) 7 Oil drain screw front 2 Oil filler screw top 8 Poly v belt 3 Exhaust gas turbocharger 9 Radiator (option) 4 Oxidation catalytic converter 5 Exhaust gas discharge 3 - 4H50 / 07.2015...

  • Page 10: Technical Data

    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 Bore/stroke 84/88 84/88 Displacement 1464 1952 Fill quantity of lubricating oil Approx.
  • Page 11 Engine type plate EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ KG ¬ D-94099 RUHSTORF GMBH www.hatz-diesel.com 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.

  • Page 12: Lubricating Oil Circuit

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

  • Page 13: Cooling Circuit

    Cooling circuit 3 - 4H50 / 07.2015...
  • Page 14 Cooling circuit 3 - 4H50 / 07.2015...
  • Page 15 Cooling circuit 3 - 4H50 / 07.2015...
  • Page 16 Cooling circuit 3 - 4H50 / 07.2015...

  • Page 17: Sealants And Adhesives

    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...
  • Page 18 Special tools and workshop equipment Assembly/disassembly cylinder head + exterior area Ident no. Designation 626 383 00 Piston ring collet chuck ø 70 - 100mm 612 099 00 Multi-tooth wrench socket M8 620 307 01 Strap wrench 612 090 01 Piston ring expander 700 217 64 Socket wrench for cyl.K E14 1/2"...
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  • Page 20 Special tools and workshop equipment Assembly/disassembly - engine Ident no. Designation 653 480 00 Counterholder for flywheel 653 466 00 Assembly pin for roller tappet 653 464 00 Magnet holder for roller tappet guide 653 517 00 Turning device for engine benches 702 517 89 Socket wrench for conrod T50 1/2"...
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  • Page 22 Special tools and workshop equipment Component servicing Ident no. Designation 629 223 01 Valve lifting tool 634 142 00 Honing tools 50-175 634 143 00 Replacement stones for honing tools 3 - 4H50 / 07.2015...
  • Page 23 3 - 4H50 / 07.2015...

  • Page 24: Special Tools And Workshop Equipment

    Special tools and workshop equipment Test bench set-up Ident no. Designation - - - - - - - - Part cannot be ordered individually, please order group - - - - - - - - Part cannot be ordered individually, please order group 652 948 00 Engine mountings F2F 647 639 00...
  • Page 25 10 (8-9) 3 (1-2) 3 - 4H50 / 07.2015...
  • Page 26 Special tools and workshop equipment Test bench set-up Ident no. Designation 624 851 01 Temperature measurement device 624 861 01 Sensor extension cable 653 290 00 Assembly table 635 303 90 Adapter flange 6-8-hole 631 147 90 Driven flange 630 705 00 Drive shaft 8-hole 630 706 00 Rod end 8-hole "new"...
  • Page 27 3 - 4H50 / 07.2015...
  • Page 28 Special tools and workshop equipment Adjustment and diagnostic equipment Ident no. Designation 624 838 92 Revolution counter for fuel pressure pipe - - - - - - - - - Part cannot be ordered individually, please order group 638 342 00 Charging cable with 12V pole clamps - - - - - - - - - Part cannot be ordered individually, please order group...
  • Page 29 3 - 4H50 / 07.2015...
  • Page 30 Special tools and workshop equipment Adjustment and diagnostic equipment Ident no. Designation - - - - - - - - - Part cannot be ordered individually, please order group - - - - - - - - - Part cannot be ordered individually, please order group - - - - - - - - - Diagnostic tool (Bosch) VCI 653 772 00...
  • Page 31 4 (1-3) 3 - 4H50 / 07.2015...
  • Page 32 Special tools and workshop equipment Cooling system Ident no. Designation 702 530 56 Radiator vacuum filling device 702 530 57 Tank for filling device 3 - 4H50 / 07.2015...
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  • Page 34 Special tools and workshop equipment Electrical equipment Ident no. Designation 700 318 32 Crimping pliers "Garant F28/95" 700 348 26 Mounting pliers "Deutsch HDT 48-00" 3 - 4H50 / 07.2015...
  • Page 35 3 - 4H50 / 07.2015...

  • Page 37: Additional Equipment

    2. Additional equipment 3 - 4H50 / 07.2015...
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  • Page 47 3. Basic engine equipment 3 - 4H50 / 07.2015...
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  • Page 89 4. Tables 3 - 4H50 / 05.2016...
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  • Page 91 Screw tightening torque General [Nm]: Nm  9.81(10) = kpm Nm  1.3558 = Lbs ft Screw quality Thread 10.9 12.9 M 10 M 12 M 14 M 16 M 18 M 20 M 22 3 - 4H50 / 05.2016...
  • Page 92 Screw tightening torque 3 - 4H50 / 05.2016...
  • Page 93 Screw tightening torque 3 - 4H50 / 05.2016...
  • Page 94 Identification on wiring diagrams (DIN 40719) Identifier Designation of the electrical components Instrument box Instrument plate Start stop automatic Starter protection module Temperature sensor Speed encoder Oil pressure sensor Signal horn Condenser Heater for fuel filter Fuse Battery Three phase alternator Flywheel alternator Indicator light for alternator control Indicator light for oil pressure...
  • Page 95 Identification on wiring diagrams (DIN 40719) Identifier Designation of the electrical components Operating hours counter Tachometer Pressure indicator Glow plug Heating flange Series resistor for glow system Resistor Series resistor with thermo time switch Glow start switch (5 - digit) Main switch Glow plug starter switch (3 - digit) Start stop switch...
  • Page 96 HATZ cable marking Terminal Designation Ground Alternator B+ For three phase alternator: D+ for flywheel alternator: terminal L on the controller Starter terminal 50 Oil pressure switch Temperature switch on the cylinder head Glow plug I Electromagnet for engine switch-off Glow plug II Start stop input Plus terminal for direct current motor speed fine adjustment...
  • Page 97 Bosch designation for cable marking Bosch Hatz German designation English designation INJ11 INJektor Bank 1 - Zylinder 1 (1. Zylinder) INJector bench 1 - cylinder 1 (1. cylinder) INJ12 INJektor Bank 1 - Zylinder 2 (4. Zylinder) INJector bench 1 - cylinder 2 (4. cylinder) INJ21 INJektor Bank 2 - Zylinder 1 (3.
  • Page 98 Cable harness max. 3 - 4H50 / 05.2016...
  • Page 99 Cable harness min. 3 - 4H50 / 05.2016...
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  • Page 114 Cable routing DPF 3 - 4H50 / 05.2016...
  • Page 115 Cable routing 3 - 4H50 / 05.2016...
  • Page 116 Cable routing 3 - 4H50 / 05.2016...
  • Page 117 Cable routing 3 - 4H50 / 05.2016...
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  • Page 123 Cable routing 3 - 4H50 / 05.2016...
  • Page 124 Cable routing 3 - 4H50 / 05.2016...
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  • Page 127 Blink code SHORT - LONG Error source: Error in the monitoring, display and control elements area Indicators or cabling Possible error: power supply from control unit other error, not in more detail Check and cabling of the Remedies: check power supply to the control otherwise HATZ must perform Error...
  • Page 128 Charge current curve 12 V Charge current [A] Engine speed [rpm] Ambient temperature 25°C Ambient temperature 80°C 3 - 4H50 / 05.2016...
  • Page 129 Charge current curve 24 V Charge current [A] Engine speed [rpm] Ambient temperature 25°C Ambient temperature 80°C 3 - 4H50 / 05.2016...
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