Hatz Diesel 3H50 Operator's Manual
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Hatz Diesel 3H50 Operator's Manual

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INCLUDES SUPPLEMENTAL INFORMATION TO
THE OWNER'S MANUAL FOR MODEL YEAR
2022 FOR EPA AND CALIFORNIA CERTIFIED
NONROAD COMPRESSION IGNITION ENGINES.
CREATING POWER SOLUTIONS.
3H50 | 4H50
OPERATOR'S MANUAL
Diesel engine
Hatz Diesel
www.hatz-diesel.com

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Summary of Contents for Hatz Diesel 3H50

  • Page 1 CREATING POWER SOLUTIONS. INCLUDES SUPPLEMENTAL INFORMATION TO 3H50 | 4H50 THE OWNER’S MANUAL FOR MODEL YEAR 2022 FOR EPA AND CALIFORNIA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. OPERATOR’S MANUAL Diesel engine Hatz Diesel www.hatz-diesel.com...

  • Page 3: Table Of Contents

    3H50, 4H50 Table of contents Table of contents Notices .........................  5 General information ....................  6 Safety ........................ 7 General information ...................... 7 3.1.1 Intended use ........................ 7 3.1.2 Machine user or machine manufacturer obligations ............ 8 3.1.3 Representation of safety notes ....................  9 3.1.4...
  • Page 4 Table of contents 3H50, 4H50 Maintenance ......................  78 General maintenance instructions .................. 78 Maintenance work...................... 79 8.2.1 Maintenance plan ...................... 79 8.2.2 Additional work on the Silent Pack .................. 82 8.2.3 Checking the intake area of the combustion air.............. 85 8.2.4...

  • Page 5: Notices

    3H50, 4H50 Notices Notices Contact data © 2021 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 manual rests entirely with Motorenfabrik HATZ, Ruh- storf.

  • Page 6: General Information

    General information 3H50, 4H50 General information Information on the document This manual was created with due care. It is exclusively intended to offer a technical description of the machine and to provide instructions on commis- sioning, operating and maintaining the machine. When operating the ma- chine, the applicable standards and legal regulations as well as any in-house regulations apply.

  • Page 7: Safety

    3H50, 4H50 Safety Safety General information Introduction This chapter contains the information you need to work safely with this ma- chine. To prevent accidents and damage to the machine, it is imperative that these safety instructions be followed. Read this chapter carefully before beginning work.

  • Page 8: 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.

  • Page 9: Representation Of Safety Notes

    3H50, 4H50 Safety All work performed on the machine must be in compliance with the informa- tion provided in this manual. Storing this manual This manual is an integral component of the machine (also when being sold). It must be stored in the direct vicinity of the machine and be accessi- ble to personnel at all times.

  • Page 10: Meaning Of Safety Symbols

    Safety 3H50, 4H50 Signal words Signal words identify the magnitude of the risk and the seriousness of possi- ble injury: Danger symbol/ Meaning signal word This signal word is used to indicate imminently DANGER dangerous situations which, if not avoided, will lead to serious injury or death.
  • Page 11 3H50, 4H50 Safety Symbol Meaning Warning of explosive substances! Warning of toxic engine exhaust! Warning of corrosive substances! Warning of heavy loads! Warning of environmental damage! Comply with this manual or additional documentation from other manufacturers or the carrier. Additional information that is useful to the reader.

  • Page 12: Safety Notes

    Safety 3H50, 4H50 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.
  • Page 13 3H50, 4H50 Safety Personal protective Pictogram Function equipment 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.
  • Page 14 Safety 3H50, 4H50 Safety equipment Safety equipment must not be modified and must not be rendered ineffective during normal operation. General safety instructions DANGER Danger to life and danger of injury due to failure to follow the warnings on the machine and in this manual.

  • Page 15: Machine-Specific Safety Instructions For Operation

    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.

  • Page 16: Machine-Specific Safety Instructions For Maintenance Work

    Safety 3H50, 4H50 DANGER Fire hazard from fuel. Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Only refuel when the engine is switched off and has cooled down. ▪ Never refuel in the vicinity of open flames or sparks that can cause ignition.
  • Page 17 3H50, 4H50 Safety Replacing parts ▪ When replacing defective components, we recommend that you use Hatz original spare parts (see chapter 2 General information, page 6). ▪ When disposing of parts that can no longer be used, do so in accordance with local environmental regulations or send them to a recycling center.

  • Page 18: Electrical Equipment

    Safety 3H50, 4H50 CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. 3.2.4 Electrical equipment Safety notes DANGER Danger to life, danger of injury or danger of property dam- age due to incorrect use of batteries.

  • Page 19: Labels

    3H50, 4H50 Safety 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.
  • Page 20 Safety 3H50, 4H50 Label Meaning Engine specification Silent Pack CAUTION! Danger of injury from rotating parts. ▪ Only operate the engine when all covers are installed. Warning of hot surfaces! Cleaning with a high pressure cleaner is prohibited! ▪ Do not spray the Hatz instrument box with a high-pressure water jet.
  • Page 21 3H50, 4H50 Safety Warning labels and information signs on the battery (option) Label Meaning 1. Fire, sparks, open flames and smoking are prohibited: avoid causing sparks when working with cables and electrical machines. Avoid short-circuits. 2. Follow the instructions on the bat- tery and in the battery user man- ual.

  • Page 22: Technical Data

    Technical data 3H50, 4H50 Technical data Engine information and filling quantities Type 3H50 4H50 Type Liquid-cooled four stroke diesel engine Combustion system Direct injection Number of cylinders Bore/Stroke 84 / 88 84 / 88 Displacement Liter 1,464 1,952 Engine oil consumption Max.
  • Page 23 3H50, 4H50 Technical data Engine specifications Model Description With turbocharger. With turbocharger, charge air cooling, cooled ex- haust gas recirculation (EGR) and diesel oxidation catalyst (DOC) TICD With turbocharger, charge air cooling, cooled ex- haust gas recirculation (EGR), diesel oxidation cata- lyst (DOC) and diesel particulate filter (DPF).
  • Page 24 Technical data 3H50, 4H50 Coolant filling quantities (engines with Hatz radiator) Hatz radiator With external expansion With integrated expansion tank tank type Filling quantity in liters * 3H50 T – 3H50 TI 12.0 12,7 3H50 TIC 12.0 12,7 3H50 TICD 12.0...
  • Page 25 3H50, 4H50 Technical data Screw tightening torque Designation Oil drain screw Drain screw on engine radiator Drain screw on charge air cooler Connection and fixing screws (M10) for protective guard (engine specification TI, TIC, TICD) Connection and fixing screws (M8) for protective guard...

  • Page 26: Engine Type Plate

    Technical data 3H50, 4H50 Engine type plate EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ GMBH KG ¬ D-94099 RUHSTORF www.hatz-diesel.com Model: Build: S/N: Power: Displ: Eng.Fam: Emission Control System: Power Category: ULTRA LOW SULFUR DIESEL FUEL ONLY. THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR MY2018 NONROAD DIESEL ENGINES.

  • Page 27: Engine Oil

    3H50, 4H50 Technical data 4.2.1 Engine serial number Breakdown of the engine serial number 133 11 15 123456 Engine type number Engine serial number Model year Fabrication number (consecutive) Engine type number The engine type number makes it possible to see if the engine is equipped with a diesel oxidation catalyst (DOC).
  • Page 28 Technical data 3H50, 4H50 CAUTION Damage to the diesel oxidation catalyst (DOC) from using unsuitable engine oil. Unsuitable engine oil diminishes the functionality and service life of the catalytic converter and diesel particulate filter. Only use engine oils with very low quantities of sulfate ash, phosphor and sulfur –...

  • Page 29: Coolant

    3H50, 4H50 Technical data 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.
  • Page 30 5 liters 0000 055 413 00 The H-series Coolant concentrate is exactly matched to the requirements of your HATZ diesel engine. Alternative radiator protection fluids If no H-series Coolant is available, other radiator protection fluids are ap- proved by HATZ:...
  • Page 31 3H50, 4H50 Technical data Manufacturer Product name Fuchs MAINTAIN FRICOFIN G 12 PLUS, MAINTAIN FRICOFIN LL, MAINTAIN FRICOFIN DP Gazpromneft- G-ENERGY ANTIFREEZE SNF, G-Energy Antifreeze Si- Lubricants Gulf Gulf Eurocool G-40 Concentrate Huiles Berliet RTO Maxigel Plus S.A. INA MAZIVA INA Antifriz BS Super Ltd.
  • Page 32 Technical data 3H50, 4H50 Manufacturer Product name Petrol Ofisi PO EXTENDED LIFE COOLANT PrixMax PrixMax MEG95 Raloy Raloy Anticongelante Concentrate (G40) Lubricantes REPSOL LU- REPSOL ANTI.REF.ORGANICO MAXIMUM QUALITY BRICANTES Sinopec SINOPEC Antifreeze B25.5 POWER COOLING NG Tedex Tedex Antifreeze OT LL...

  • Page 33: Fuel

    3H50, 4H50 Technical data The following values must not be exceeded: Water quality Max. Water hardness (°dGH) Water hardness (mmol/l) Chloride content (ppm) Sulfate content (ppm) The coolant mixture ratio must not be below or exceed the following concen- tration:...
  • Page 34 Technical data 3H50, 4H50 CAUTION Danger of malfunctions due to old fuel. When diesel fuel is stored in a fuel tank or canister for lengthy periods, deposits may form on account of fuel aging. These de- posits result in malfunctions due to clogged fuel filters and dam- age to the injection system.

  • Page 35: Engine Overview

    3H50, 4H50 Engine overview Engine overview Designation of components Model – TIC intake side Intake opening for combustion air Oil filler plug, top (option) Oil filter Fuel main filter Side oil drain screw HATZ Operator’s Manual...
  • Page 36 Engine overview 3H50, 4H50 Fuel prefilter Drain plug with integrated water level sensor Electric fuel pump Engine type plate Starter (low mounting position) Dipstick Oil filler plug, bottom Oil filler plug, middle (option) Crankcase ventilation Operator’s Manual HATZ...
  • Page 37 3H50, 4H50 Engine overview Model – TIC/TICD exhaust side Lifting eyes DPF system with diesel oxidation catalytic converter and diesel particulate filter (TICD model) Turbocharger Engine foot Diesel oxidation catalytic converter DOC (TIC model) Exhaust outlet Starter (high mounting position)
  • Page 38 Engine overview 3H50, 4H50 Model – OPU intake side NOTICE The Open Power Unit (OPU) is a complete system which, in ad- dition to the engine, also includes all of the components required for cooling. Intake opening for combustion air Rain cap Operator’s Manual...
  • Page 39 3H50, 4H50 Engine overview Air filter (optional) Dust discharge valve Lifting eyes Engine control unit Plug holder with integrated relay, glow control unit and fuse holder Oil filter Fuel main filter Side oil drain screw Fuel prefilter Drain plug with integrated water level sensor...
  • Page 40 Engine overview 3H50, 4H50 Model – OPU exhaust side Radiator with integrated expansion tank Sealing cap for coolant Oil filler plug, top (option) Turbocharger Diesel oxidation catalyst (DOC) Exhaust outlet Starter (high mounting position) Three phase alternator Belt guard (option) Oil drain screw, front Operator’s Manual...

  • Page 41: Hatz Instrument Box

    3H50, 4H50 Engine overview Encapsulated model – Silent Pack NOTICE The Silent Pack is an Open Power Unit (OPU) that is sur- rounded by a noise and weather protection capsule. The mainte- nance covers (4) and (6) can be removed for daily maintenance work.
  • Page 42 Engine overview 3H50, 4H50 Speed adjustment Engine type plate Drain plug with integrated water level sensor Fuel prefilter Components of the electronic engine control unit Pos. Designation Figure Crankshaft speed sensor Operator’s Manual HATZ...
  • Page 43 3H50, 4H50 Engine overview Pos. Designation Figure Air filter differential pressure sensor Rail pressure sensor Rail pressure control valve EGR valve Coolant level sensor (integrated in external expan- sion tank) Coolant temperature sensor Coolant level sensor (for radiator with integrated...
  • Page 44 Engine overview 3H50, 4H50 Pos. Designation Figure Air mass meter (TICD model) Charge air pressure and charge air temperature sensor Exhaust gas temperature sensor (TICD model) Differential pressure sensor (TICD model) Low fuel pressure and fuel temperature sensor Water level sensor...
  • Page 45 3H50, 4H50 Engine overview Fuses Overview - fuse assignment 3H50TIC, 4H50TIC Pos. Consumer Fuse Voltage supply for control unit Signal inputs for control unit Glow plugs Voltage supply for additional consumers Fuel pump Starter, terminal 50 HATZ Operator’s Manual...
  • Page 46 Engine overview 3H50, 4H50 Overview - fuse assignment 3H50T, 3H50TICD, 4H50TICD Pos. Consumer Fuse Central electrical system Signal inputs for control unit Fuel pump Glow plugs Voltage supply for control unit Ignition, terminal 15 Starter, terminal 50 Ignition, terminal 15 (for additional consumers that are switched via the ignition lock) Voltage converter (only for 24 V system)
  • Page 47 3H50, 4H50 Engine overview HATZ instrument box Overview Starting key Pushbutton Pre-glow indicator Operating indicator Charge control Oil pressure indicator Air filter service indicator Engine temperature indicator Maintenance interval indicator Engine fault Regeneration of diesel particulate filter required (TICD model)
  • Page 48 Engine overview 3H50, 4H50 Indicators The function of all indicators is checked when the starting key is turned. They flash or light up for different times. If there is a fault, the applicable indi- cator does not go out after the engine start or it lights up again during opera- tion.
  • Page 49 3H50, 4H50 Engine overview Symbol Meaning Air filter service indicator ▪ lights: Clean or renew the filter cartridge at the next opportu- nity. ▪ flashes + engine fault flashes: Immediately clean or replace the filter cartridge. For more information, see section 8.2.15 Servicing the air filter (optional), page 116.
  • Page 50 Engine overview 3H50, 4H50 Symbol Meaning Engine fault This indicator lights up or flashes if there are engine faults. Check the following to find the fault: ▪ Coolant level (see section 8.2.5 Checking the cooling system, page 88) ▪ Water separator (see section 8.2.12 Draining the water separator, page 110)
  • Page 51 3H50, 4H50 Engine overview Symbol Meaning Regeneration of the diesel particulate filter has started (see section 7.7 Regenerating the diesel particulate filter, page 73). Regeneration of the diesel particulate filter was blocked (see section 7.7 Regenerating the diesel particulate filter, page 73).

  • Page 52: Transport, Assembly And Commissioning

    Transport, assembly and commissioning 3H50, 4H50 Transport, assembly and commissioning Transport Safety notes WARNING Danger of injury from improper lifting and transport. Danger of crushing from the engine falling or tipping. ▪ The machine may only be lifted using the lifting points (1).
  • Page 53 3H50, 4H50 Transport, assembly and commissioning Access to the lifting eyes with the Silent Pack Overview Control side maintenance lid Top maintenance cover Holder for the air filter Clamp-type fasteners for control side maintenance cover Clamp-type fasteners for top maintenance cover HATZ Operator’s Manual...
  • Page 54 Transport, assembly and commissioning 3H50, 4H50 Sealing lip Fixing screws for holder for the air filter (4) Procedure Step Activity Turn clamp-type fasteners (1) to the left up to the stop.Tip main- tenance cover on the bottom to the outside and lift away up- wards.

  • Page 55: Installation Notes

    HATZ service station. For contact data, see chapter 1 "Notices", page 5 or www.hatz-diesel.com. Installation notes HATZ diesel engines are efficient, robust, and have a long service life. Therefore, they are usually installed in machines that are used for commer- cial purposes.

  • Page 56: Preparations For Commissioning

    Transport, assembly and commissioning 3H50, 4H50 ▪ Parts of the exhaust gas system and the engine surface become hot dur- ing operation and may 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.

  • Page 57: Filling Engine Oil (First Filling)

    3H50, 4H50 Transport, assembly and commissioning Filling engine oil (first filling) Engines are normally delivered without an engine oil filling. Safety note CAUTION Danger of later engine damage. ▪ Operating the engine with an oil level below the min. mark or above the max.

  • Page 58: Filling The Cooling System

    Transport, assembly and commissioning 3H50, 4H50 Procedure Step Activity Pull out the dipstick (1) and clean it. Depending on the model, unscrew oil filler plug (2), (4) or (5). Fill with engine oil. For the specification and viscosity, see section 4.3 Engine oil, page 27.
  • Page 59 3H50, 4H50 Transport, assembly and commissioning Overview External expansion tank Integrated expansion tank Expansion tank for coolant Sealing cap MAX - Maximum coolant level MIN - Minimum coolant level Procedure Step Activity Open the sealing cap (2). HATZ radiator with integrated expansion tank Top up the coolant to the edge (3) of the pipe section.

  • Page 60: Starting The Engine For The First Time Or After A Fuel Filter Replacement

    Transport, assembly and commissioning 3H50, 4H50 Step Activity Check 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. Check the cooling system for leaks, retighten the hose clips if necessary (see section 8.2.5 Checking the cooling system, page...
  • Page 61 3H50, 4H50 Transport, assembly and commissioning NOTICE See also starting instructions in the documentation for the com- plete machine. Before starting Before starting the engine, several tests need to be performed to ensure the machine is working properly. Step Test The machine is standing securely and on a level surface.
  • Page 62 Transport, assembly and commissioning 3H50, 4H50 Operating indicator Charge control Oil pressure indicator Ignition lock Operation Start NOTICE For further details on the instrument box, see section 5.3 HATZ instrument box, page 47. Procedure NOTICE ▪ Start for max. 20 seconds. If the engine is still not running after that, turn the starting key back to position "0"...
  • Page 63 3H50, 4H50 Transport, assembly and commissioning Step Activity Starting the engine Turn the starting key to position "I" again. If the pre-glow indicator goes out, turn the starting key to posi- tion "II". As soon as the engine is running, release the starting key.

  • Page 64: Operation And Use

    Operation and use 3H50, 4H50 Operation and use Safety notes NOTICE Comply with the safety chapter! Follow the basic safety instructions in 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.

  • Page 65: Performing Tests

    3H50, 4H50 Operation and use 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. ▪...

  • Page 66: Starting The Engine

    Operation and use 3H50, 4H50 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.
  • Page 67 3H50, 4H50 Operation and use Operating indicator Charge control Oil pressure indicator Engine temperature indicator Ignition lock Operation Start NOTICE For further details on the instrument box, see section 5.3 HATZ instrument box, page 47. Procedure NOTICE ▪ Start for max. 20 seconds. If the engine is still not running after that, turn the starting key back to position "0"...

  • Page 68: Switching Off The Engine

    Operation and use 3H50, 4H50 Step Activity As 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 (4) and oil pressure indicator (5) go out.
  • Page 69 3H50, 4H50 Operation and use NOTICE See also instructions in the documentation for the complete ma- chine. Overview – HATZ instrument boxes Starting key Ignition lock Operation Procedure Step Activity Turn the starting key (1) to position "0". The engine switches off.

  • Page 70: Check The Oil Level

    Operation and use 3H50, 4H50 Check the oil level 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. ▪ Operating the engine with an oil level below the min. mark or above the max.
  • Page 71 3H50, 4H50 Operation and use Dipstick (depending on the model) Oil filler plug, top (option) Oil refilling container Oil filler plug, bottom Oil filler plug, middle (option) Procedure — Checking oil level/adding oil Step Activity Switch off the engine and wait several minutes for the engine oil to collect in the crankcase.

  • Page 72: Refueling

    Operation and use 3H50, 4H50 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.

  • Page 73: Regenerating The Diesel Particulate Filter

    3H50, 4H50 Operation and use NOTICE Never run the tank empty if possible, as otherwise air can enter the fuel system. This can lead to damage to the injection sys- tem. If the tank runs dry nevertheless, the fuel system must be drained prior to the next start (see section 6.6 Starting the en-...
  • Page 74 Operation and use 3H50, 4H50 WARNING Danger of injury from hot engine exhaust gases. During regeneration of the diesel particulate filter, the exhaust gas flow and exhaust gas system achieve temperatures that can lead to serious burn injuries. ▪ Ensure that nobody is endangered by the hot exhaust gases or the hot exhaust gas system.
  • Page 75 3H50, 4H50 Operation and use Automatic regeneration When indicator (2) lights up, this indicates that automatic regeneration is due. If indicator (4) lights up in addition, automatic regeneration has started. Automatic regeneration only starts under the following conditions: ▪ The regeneration block is switched off (see section Blocking regeneration).
  • Page 76 Operation and use 3H50, 4H50 Step Activity Starting manual regeneration ▪ Press button (1) for at least 5 seconds. Indicator (2) flashes, indicator (4) lights up and operating indicator (6) goes out. The regeneration process has started and takes approx. 15 to 30 minutes. Note: During manual regeneration ▪...
  • Page 77 3H50, 4H50 Operation and use Blocking regeneration Step Activity Press button (1) briefly while the engine is running (1-3 sec- onds). When indicator (5) lights up, regeneration is blocked. In this case, automatic and manual regeneration will not be able to start and an active regeneration is stopped. Pressing the button again deactivates the block and indicator (5) goes out.

  • Page 78: Maintenance

    Maintenance 3H50, 4H50 Maintenance General maintenance instructions Safety notes WARNING Danger of injury from failure to follow the Operating Instruc- tions and from performing unauthorized tasks on the ma- chine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is avail- able.

  • Page 79: Maintenance Work

    3H50, 4H50 Maintenance ▪ 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 re- quire maintenance are easily accessible.
  • Page 80 Maintenance 3H50, 4H50 Symbol Maintenance interval Maintenance step/check Section Every Check the oil level. 7.5 Check the oil 8–15 operating hours level, page 70 or every day before Check the intake area of the 8.2.3 Checking the starting combustion air. intake area of the...
  • Page 81 3H50, 4H50 Maintenance Symbol Maintenance interval Maintenance step/check Section Every Change the air filter cartridge 8.2.15 Servicing the 500 operating hours (primary filter) air filter (optional), or when indicated, at page 116 least every 12 months When indicated, at Drain the water separator 8.2.12 Draining the...

  • Page 82: Additional Work On The Silent Pack

    Maintenance 3H50, 4H50 8.2.2 Additional work on the Silent Pack Safety notes WARNING Danger of injury from rotating parts. Touching the fans or poly v belts can lead to serious injury when the engine is running. ▪ Only operate the engine when all covers are installed.
  • Page 83 3H50, 4H50 Maintenance Control side maintenance lid Top maintenance cover Holder for the air filter Side panel on exhaust gas side Access cover to the drain plug on the radiator Clamp-type fasteners for control side maintenance cover Clamp-type fasteners for top maintenance cover...
  • Page 84 Maintenance 3H50, 4H50 Fixing screws for holder for the air filter (4) Fixing screws for side panel exhaust side (12) Fixing screws for access lid (5 pieces) Access to the service points With the Silent Pack, the engine is surrounded by a noise and weather pro- tection capsule.

  • Page 85: Checking The Intake Area Of The Combustion Air

    3H50, 4H50 Maintenance Step Activity Remove the side panel on the exhaust gas side (D) Remove the top maintenance cover (B) Remove the air filter fastening (C). Unscrew the fixing screws (5). Remove the side trim panel (D). Remove the access cover (E) to the drain plug on the radiator Unscrew the fixing screws (6).
  • Page 86 Maintenance 3H50, 4H50 Overview (HATZ air filter) Intake opening for combustion air Dust discharge valve Rubber lips OK Rubber lips deformed Procedure Step Activity Check the intake opening (1) for coarse contamination such as leaves, heavy dust deposits, etc., and clean if necessary.

  • Page 87: Checking The Radiator Fins For Dirt Accumulation

    3H50, 4H50 Maintenance Step Activity Make sure that the rubber lips (3) run parallel to each other. The gap between the rubber lips must be a maximum of 2 mm. Deformed rubber lips (4) impair the function of the precleaner, thus shortening the maintenance interval of the air filter. Re- place the dust discharge valve if required.

  • Page 88: Checking The Cooling System

    Maintenance 3H50, 4H50 Overview Radiator fins Procedure Step Activity Check the radiator fins (1) for coarse contamination such as leaves, heavy dust deposits, etc., and clean if necessary (see the chapter 8.2.7 Engine cleaning, page 97). 8.2.5 Checking the cooling system...
  • Page 89 3H50, 4H50 Maintenance CAUTION Danger of burns. There is a danger of burns when working on a hot cooling sys- tem. The cooling system is pressurized when the engine is hot. ▪ Let the engine cool. ▪ Wear safety gloves.
  • Page 90 Maintenance 3H50, 4H50 Procedure for topping up coolant Step Activity Carefully open the sealing cap (2). Top up prepared coolant to the MAX mark on the expansion tank. For the preparation of the coolant, see section 4.4 Coolant, page 29.

  • Page 91: Changing The Engine Oil And Oil Filter

    3H50, 4H50 Maintenance Procedure Step Activity Check the cooling system for leaks and rectify the cause imme- diately - in case of doubt consult HATZ Service for advice. When hose connections are loose, retighten the hose clips (1). 8.2.6 Changing the engine oil and oil filter This chapter contains the following sections: ▪...
  • Page 92 Maintenance 3H50, 4H50 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.
  • Page 93 3H50, 4H50 Maintenance Step Activity Lightly oil the sealing lip (3) of the new oil filter. Screw in the oil filter and tighten it by hand. Overview – Vertical attachment Oil filter Collar on the oil filter Shaped element Sealing surface...
  • Page 94 Maintenance 3H50, 4H50 Procedure Step Activity Loosen the oil filter (1) with a strap wrench or similar and un- screw 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.
  • Page 95 3H50, 4H50 Maintenance Procedure Step Activity Keep a container ready for collecting the used oil. The container must be large enough to hold the entire amount of engine oil. For the engine oil capacity, see section 4.1 Engine information and filling quantities, page 22.
  • Page 96 Maintenance 3H50, 4H50 Step Activity Remove the drain hose and reattach the sealing screw. Filling the engine oil Overview Dipstick (depending on the model) Oil filler plug, top (option) Oil refilling container Oil filler plug, bottom Oil filler plug, middle (option)

  • Page 97: Engine Cleaning

    3H50, 4H50 Maintenance Step Activity Fill with engine oil. For the specification and viscosity, see section 4.3 Engine oil, page 27. For the filling quantity, see section 4.1 Engine information and filling quantities, page 22. Reinsert the dipstick. Pull out the dipstick and check the oil level.
  • Page 98 Maintenance 3H50, 4H50 CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. CAUTION Danger of injury. When working with compressed air, foreign bodies may fly into your eyes.
  • Page 99 3H50, 4H50 Maintenance NOTICE In case of heavy contamination, shorten the maintenance inter- vals accordingly (see chapter 8.2.1 Maintenance plan, page 79). Overview Radiator fins Direction of flow of the cooling air with suction fan Direction of flow of the cooling air with forced-draught fan...

  • Page 100: Checking The Poly V Belt

    Maintenance 3H50, 4H50 8.2.8 Checking the poly v belt This section contains the following subsections: ▪ Checking the poly v belt for damage ▪ Checking and setting the belt tension Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot engine.
  • Page 101 3H50, 4H50 Maintenance Check the poly v belt for damage. Overview Pulley Poly v belt Damage to the poly v belt Transverse cracks on the rear Fraying on the edges Transverse cracks in multiple ribs Broken ribs Procedure Step Activity Check the poly v belt (2) for the following damage: ▪...
  • Page 102 Maintenance 3H50, 4H50 Checking and setting the belt tension Model without A/C compressor The following description only applies to engines without A/C compressor. For the model with A/C compressor, a belt tensioner with spring preload al- ways ensures the correct belt tension. The checking and setting of the belt tension is omitted here.
  • Page 103 3H50, 4H50 Maintenance Setting values for the belt tension The pretensioning force or the vibration frequency of the belt is decisive for adjustment of the belt tension. For this, we recommend the use of the DM.16 belt tension meter from Facom or a frequency meter. If neither of these me- ters are available, please contact your nearest HATZ Service.

  • Page 104: Replacing The Poly V Belts

    Maintenance 3H50, 4H50 8.2.9 Replacing the poly v belts This section contains the following subsections: ▪ Belt run ▪ Preparatory activities ▪ Engine without A/C compressor ▪ Engine with A/C compressor Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine.
  • Page 105 3H50, 4H50 Maintenance Preparatory activities Overview Belt guard Fixing screws for the belt guard Protective guard (left half) Connecting screws, protective guard halves (top and bottom) Fixing screws, protective guard (top and bottom) Procedure Step Activity Unscrew the optional belt guard (1). Unscrew the fixing screws (2) for this.
  • Page 106 Maintenance 3H50, 4H50 Engine without A/C compressor Overview Alternator Upper fixing screw on the generator Lower fixing screw on the generator Poly v belt Fan blade Procedure Step Activity Undo fixing screws (2) and (3). Turn the generator (1) in the direction of the arrow to the stop.
  • Page 107 3H50, 4H50 Maintenance Step Activity Insert the connection and fixing screws for the protective guard. For the tightening torque, see section 4.1 Engine information and filling quantities, page 22. Install the belt guard. Engine with A/C compressor Safety note CAUTION Danger of injury.

  • Page 108: Changing The Oil Separator Of The Crankcase Ventilation

    Maintenance 3H50, 4H50 Procedure Step Activity Insert a 3/8" square key into the groove in the belt tensioner (1). Turn the belt tensioner in the direction of the arrow, thus reliev- ing the tension of the poly v belt (2). Remove the loose poly v belt from the pulley.
  • Page 109 3H50, 4H50 Maintenance Overview Mounting bolts (captive) Breather cap Oil separator cartridge Vent hose Procedure Step Activity Release the four mounting bolts (1) on the breather cap (2). Carefully lift the breather cap. If necessary, release the vent hose (4).

  • Page 110: Checking The Screw Connections

    Maintenance 3H50, 4H50 8.2.11 Checking the screw connections Safety note NOTICE ▪ Only retighten loose screw connections. Screw connections can be secured with thread locking ad- hesive or tightened to a defined torque. Retightening tight screw connections can cause damage.
  • Page 111 3H50, 4H50 Maintenance Overview Bleed screw Drain plug with integrated water level sensor Water level sensor connector Drain socket for extension hose Hose clip (for a fuel tank positioned low) Procedure Step Activity Place a suitable container under the drain socket (4) of the drain plug (2).

  • Page 112: Changing The Fuel Prefilter

    Maintenance 3H50, 4H50 8.2.13 Changing the fuel prefilter 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.
  • Page 113 3H50, 4H50 Maintenance Overview Hose clip on fuel feed line Fuel prefilter Drain plug with integrated water level sensor Water level sensor cable Strap wrench Gasket Procedure Step Activity Lock the fuel supply line on the fuel prefilter. Place a suitable container under the filter to collect emerging fuel.

  • Page 114: Changing The Main Fuel Filter

    Maintenance 3H50, 4H50 Step Activity Release the fuel feed line and connect the cable of the water level sensor. Start the engine and perform a test run. NOTE: When starting the engine, adhere to the procedure in "6.6 Starting the engine for the first time or after a fuel filter re- placement, page 60".
  • Page 115 3H50, 4H50 Maintenance CAUTION Danger of injury. Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. ▪ If there is contact with the skin, thoroughly wash the af- fected areas of the skin with soap and water.

  • Page 116: Servicing The Air Filter (Optional)

    Maintenance 3H50, 4H50 Strap wrench Gasket Procedure Step Activity Block the fuel feed line (1) using the hose clip (2). Place a suitable container under the filter to collect emerging fuel. Unscrew the main fuel filter (3) and dispose of it according to lo- cal environmental regulations.
  • Page 117 3H50, 4H50 Maintenance NOTICE ▪ 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.
  • Page 118 Maintenance 3H50, 4H50 Sealing surfaces Replacing the primary/secondary filters Step Activity Open the retaining clips (2) and remove the air filter cover (3). Pull out the primary filter (6) and either replace (recommended) or clean (see below). The primary filter must be replaced every 12 months at the latest;...

  • Page 119: Changing Coolant

    3H50, 4H50 Maintenance 8.2.16 Changing coolant This section contains the following subsections: ▪ Draining the cooling system ▪ Rinsing the cooling system ▪ Filling the cooling system Safety notes CAUTION Danger of scalding and risk of environmental damage due to hot coolant.
  • Page 120 Maintenance 3H50, 4H50 Overview Expansion tank for coolant Sealing cap MAX - Maximum coolant level MIN - Minimum coolant level Drain plug on the radiator Seal ring Screw plug for drain valve Drain hose Draining the cooling system Step Activity Provide a container to collect the used coolant.

  • Page 121: Draining The Charge Air Cooler

    3H50, 4H50 Maintenance Step Activity Model with drain plug Unscrew the drain plug (5) and drain the coolant into the con- tainer. Screw in the drain plug (5) with a new gasket (6) and tighten. Tightening torque: 50 Nm. Model with drain valve Remove the screw plug (7).
  • Page 122 Maintenance 3H50, 4H50 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 Engine radiator Charge air cooler Drain screw on charge air cooler...

  • Page 123: Resetting The Maintenance Interval Indicator

    3H50, 4H50 Maintenance 8.2.18 Resetting the maintenance interval indicator After completion of maintenance work reset the maintenance interval indica- tor. The counter starts again at zero and indicates when the next larger ser- vice is due. Overview – HATZ instrument boxes...

  • Page 124: Faults

    Faults 3H50, 4H50 Faults Troubleshooting 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. Indicator for engine fault on the HATZ instrument box is flashing.
  • Page 125 3H50, 4H50 Faults At low temperatures (engine does not start) Possible causes Remedy Chapter Oil is too viscous and Change the engine oil and oil 8.2.6 Changing causes a too low filter. the engine oil starter speed. Add engine oil with a suitable and oil filter, viscosity class.
  • Page 126 Faults 3H50, 4H50 The engine loses power and speed. Possible causes Remedy Section Engine running due to Switch off the engine, wait at 7.4 Switching off a fault in the emer- least 1 minute, then restart the the engine, page gency run function (in- engine.

  • Page 127: Start Support

    3H50, 4H50 Faults Possible causes Remedy Chapter Thermostat or water Contact HATZ Service. pump faulty. Coolant level too low. Check the cooling system. 8.2.5 Checking the cooling sys- tem, page 88 Start support Safety notes DANGER Danger of explosion due to the generation of sparks.
  • Page 128 Faults 3H50, 4H50 WARNING Danger of injury or property damage due to incorrectly car- ried out start support. If the instructions for the start support are not adhered to pre- cisely, there is a danger of explosion due to the generation of sparks as well as a danger of chemical burns due to leaking bat- tery acid.
  • Page 129 3H50, 4H50 Faults Battery Discharged battery Current emitting battery Red start support cable (positive (+) terminal) Clamp pliers on the positive (+) terminal of the discharged bat- tery Clamp pliers on the positive (+) terminal of the current emitting battery Black start support cable (negative (–) terminal)
  • Page 130 Faults 3H50, 4H50 Overview – 24 volt model NOTICE The 24 volt model is supplied with two 12 volt batteries that are connected in series with a connection cable (C). Batterys Discharged batteries Current emitting batteries Connection cable between the batteries Red start support cable (positive (+) terminal)
  • Page 131 3H50, 4H50 Faults Procedure – 24 volt model Step Activity Either two batteries (12 volts) with connection cable (C) can be used for start support in accordance with Overview – 24 volt model or an external device with a 24 volt system. See also the instructions in the documentation for the external device.

  • Page 132: Storage And Disposal

    Storage and disposal 3H50, 4H50 Storage and disposal 10.1 Storing the machine 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.
  • Page 133 3H50, 4H50 Storage and disposal NOTICE Comply with the safety chapter! Follow the basic safety instructions in chapter 3 Safety, page 7. Storing the machine for a lengthy period Take the following measures if you intend to take the machine out of service...

  • Page 134: Disposing Of The Machine

    Storage and disposal 3H50, 4H50 Recommissioning Step Activity Remove all covers. Check the cables, hoses and lines for cracks and leak tightness. Check the engine oil level. Check the coolant level. Install the battery in accordance with the Operator's Manual for the machine.

  • Page 135: Proof Of Quality

    Motorenfabrik Hatz GmbH & Co.KG Ernst-Hatz-Straße 16 D-94099 Ruhstorf a. d. Rott hereby declares that the incomplete machine: product description: Hatz diesel engine Type designation and as of serial number: 3H50T = 17810, 3H50TIC = 13510, 3H50TICD = 16410, 4H50TIC = 13610, 4H50TICD = 16510 satisfies the following basic safety and health protection requirements in acc.

  • Page 136: Epa And Carb Certified Engines

    EPA AND CARB CERTIFIED ENGINES 3H50, 4H50 EPA AND CARB CERTIFIED ENGINES SUPPLEMENTAL INFORMATION TO THE OWNER'S MANUAL FOR MODEL YEAR 2022 FOR EPA AND CALIFORNIA CERTIFIED NONROAD COMPRESSION IGNITION ENGINES. EPA AND CALIFORNIA EMISSION CONTROL SUPPLEMENTAL WARRANTY STATEMENT. Operator’s Manual...
  • Page 137 3H50, 4H50 EPA AND CARB CERTIFIED ENGINES EPA AND CARB EMISSION CONTROL WARRANTY STATEMENT. YOUR WARRANTY RIGHTS AND OBLIGATIONS. The California Air Resources Board and Motorenfabrik Hatz GmbH & Co. KG is pleased to explain the emission control system warranty on your Model Year 2022 engine.
  • Page 138 EPA AND CARB CERTIFIED ENGINES 3H50, 4H50 If any emission-related part on your engine is defective, the part will be re- paired or re- placed by Motorenfabrik Hatz GmbH & Co. KG. The warranty period shall begin: ▪ on the date the equipment is first delivered to the first retail purchaser, or;...
  • Page 139 Customer Assistance If you have any questions regarding your warranty rights and responsibilities, you should contact HATZ DIESEL OF AMERICA, Inc. at (262)-544-0254. What is Not Covered by the Emission Warranty Please note that Emission Warranty does not cover: ▪...
  • Page 140 EPA AND CARB CERTIFIED ENGINES 3H50, 4H50 ▪ Equipment with an altered or disconnected hourmeter where the hours cannot be determined. Equipment normally operated outside the United States. ▪ Non-defective parts replaced by other than Motorenfabrik Hatz dealers. What is Covered by the Emission Warranty...
  • Page 141 SUPPLEMENTAL LIMITED WARRANTY. Hatz Diesel of America, Inc. hereinafter referred to as “HATZ” warrants each of the above-listed parts when installed in a new engine sold by Hatz to be free from defects in material and workmanship under normal use and ser-...
  • Page 142 EPA AND CARB CERTIFIED ENGINES 3H50, 4H50 Hatz reserves the right to modify, alter, and improve any engine or parts in accordance with the applicable regulations without incurring any obligation to replace any engine or parts previously sold with such modified, altered, or improved engine or parts.
  • Page 143 3H50, 4H50 EPA AND CARB CERTIFIED ENGINES WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. ¬ Always start and operate the engine in a well-ventilated area.
  • Page 144 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 0000 436 006 11 - 12.2021 Printed in Germany USA - EPA IV - CARB CREATING POWER SOLUTIONS.

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