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Hatz Diesel 4H50TIC Workshop Manual
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Hatz Diesel 4H50TIC 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 4H50TIC

  • Page 1 Workshop Manual 4 H 50 TIC 439 002 00 - 07.2015e Printed in Germany...
  • Page 2 1. General 3 - 4H50 / 07.2015...
  • Page 3 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 4 Cooling circuit diagram 4H50TIC/TICD Coolant expansion tank Oil radiator EGR main Cabin heating Radiator Valve radiator Bypass EGR pre- radiator Thermostat Crank case output manifold Cylinder 1-4 ; Cylinder head 1-4 EGR manifold Crank case input manifold Water pump pressure side...
  • Page 5 Cooling circuit diagram 4H50 – within the engine Crank case output manifold Air vent cylinder head Bypass thermostat Crank case Input manifold Water pump pressure side Water pump Return expansion tank Return coolant radiator Water pump intake...
  • Page 6 Cooling circuit diagram 4H50 – radiator and cabin heating Air vent radiator Intake from crank case output manifold Return pipe cabin heating Input radiator Supply from radiator to water pump intake Supply cabin heating...
  • Page 7 Cooling circuit diagram 4H50 – exhaust gas recirculation and oil radiator EGR Valve Return from EGR to coolant manifold EGR manifold EGR pre-cooler Air vent expansion tank EGR main cooler Coolant manifold Intake EGR manifold crankcase manifold Intake from EGR manifold to oil radiator Return from coolant manifold Return from oil radiator...

  • Page 8: Sealants And Adhesives

    Sealants and adhesives Application of sealant and adhesive material: Identification letters in the drawings provide indications, which are decoded below. This is the same listing that is used in our spare parts list. A = 502 230 01 Loctite Activator 500 ml B = 502 231 01 Loctite 574...
  • Page 9 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"...
  • Page 10 3 - 4H50 / 07.2015...
  • Page 11 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"...
  • Page 12 3 - 4H50 / 07.2015...
  • Page 13 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 14 3 - 4H50 / 07.2015...
  • Page 15 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 Axle height adjustment 647 639 00...
  • Page 16 3 (1-2) 3 - 4H50 / 07.2015...
  • Page 17 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 18 3 - 4H50 / 07.2015...
  • Page 19 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 20 3 - 4H50 / 07.2015...
  • Page 21 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 22 4 (1-3) 3 - 4H50 / 07.2015...
  • Page 23 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...
  • Page 24 3 - 4H50 / 07.2015...
  • Page 25 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 26 3 - 4H50 / 07.2015...

  • Page 27: Additional Equipment

    2. Additional equipment 3 - 4H50 / 07.2015...
  • Page 28 Z 01 Main fuel filter Absolute cleanliness! Protective caps may only be removed from the parts directly before mounting! Filter head 2 x washer 10.5 2 x cylinder screw M 10x30 46 Nm KRST main filter 2 x sealing ring A 16x22 Ring nipple KRST line...
  • Page 29 Z 02 Suction hose Hexagon nut M 6 2 x cylinder screw M 6x12 9.5 Nm Bracket Cylinder screw M 6x16 9.5 Nm Pressure sensor Sleeve Adapter fittings...
  • Page 30 Z 03 Oxidation catalytic converter 4 x hexagon nut VM 8 23 Nm Gasket Oxidation catalytic converter 2 x spacers (incl. piping, flange and support) 2 x washer 10.5 2 x cylinder screw M 10x60 46 Nm Fastening 2 x washer 10.5 2 x washer A 8.4 2 x cylinder screw M 10x30...
  • Page 31 Z 05 Alternator Washer 8.4 Hexagon nut M 8 Cylinder screw M 8x20 Washer B 8.4 23 Nm Flange sleeve Tensioning arm Cylinder screw M 8x35 23Nm Alternator 14V/110A Poly v belt 2 x spring pin 12x10 6PK 768 Pretensioning of new Hexagon nut M 10 belt: 480 + 50 N...
  • Page 32 Z 05 Starter Starter bracket cover 2 x washer 10.4 2 x cylinder screw M 10x35 46 Nm Starter 12V 2.2 kW 2 x washer 10.4 2 x cylinder screw M 10x45 46 Nm...
  • Page 33 Z 06 Engine base 3 x engine base Cover plate with oil filler 15 x washer 10.5 and engine base 9 x cylinder screw M 10x55 46 Nm 2 x cylinder screw M 10x35 (in the crankcase) 46 Nm O-ring Ø7x2 FPM 4 x cylinder screw M 10x40 (in connection housing)
  • Page 34 Z 07 Oil cooler Oil cooler_KTR Double nipple Secure with Loctite 648 40 Nm Threaded pin M 8x10 Throw away filter 10 Nm...
  • Page 35 Z 07 Oil cooler Pipe clamp Shaped hose piece RSGU 1.25/15 8 x 3 fastened with Washer 6.4 2 x hose clamp DIN 3017-A 10-16x7.5 Hexagon bolt 1.5 Nm M 6x16 9.5 Nm Distributor Shaped hose piece fastened with 2 x hose clamp Shaped hose piece DIN 3017-A 12-22x9 16 x 4.5...
  • Page 36 Z 30 Fan Exhaust fan Spacer for fan 3 x spring washer A 6 3 x cylinder screw M 6x35 9.5 Nm...

  • Page 37: Basic Engine Equipment

    3. Basic engine equipment 3 - 4H50 / 07.2015...
  • Page 38 M 01 Cylinder crankcase Dipstick complete Oil pressure sensor DS-M1-TF 37.5 Nm Check valve Heed installation posi- tion!
  • Page 39 2 x cylinder pin 6 m6x12 M 01 Cylinder crankcase press in to specifi ed dimension 4 mm Secure tube connectors with Loctite 648 and press into cylinder block up to the stop Secure check valve (Provent) with Loctite 243 Oil overpressure valve: 12.5 ±...
  • Page 40 M 01 Cylinder crankcase Piston cooling complete Oil spray nozzle Valve screw N8 27 ± 2 Nm...
  • Page 41 M 02 Crankshaft Insert main bearing Insert thrust washer with halves into cylinder grease. block main bearing Oil pockets point to the bracket and moisten crankshaft sliding sur- with engine oil. faces! Heed the correct posi- tion of the oil holes and the position groove.
  • Page 42 M 02 Crankshaft Thread crankshaft into cylinder block. Ensure axial play of the crankshaft through correct mounting of the main bearing bracket with thrust washers. Before tightening the screws on the main bearing bracket, put the crankshaft and the main bearing bracket in the specifi...
  • Page 43 M 02 Crankshaft Tighten main bearing bracket in the specifi ed sequence. Tightening torque: 1st level: 10 Nm 2nd level: 45 Nm 3rd level: 90 Nm...
  • Page 44 M 04 Camshaft Cylinder pin 8 x 50 Threaded pin M10 x 10 Mount with Loctite 243 Tighten threaded pin up Grease camshaft bear- to stop ing points with engine (max. 5 Nm), oil and insert camshaft then loosen half to into cylinder block.
  • Page 45 M 02 Crankshaft gear wheel Place crankshaft gear wheel on crankshaft, heeding the correct positioning of the mark- ings! Press spring pin into crankshaft gear wheel to specifi ed dimension.
  • Page 46 M 01 Connector housing Apply sealing agent Loctite 5910 according to the black WDRI 55x70x8 curve. Oil slightly and press in until fl ush with fl ange surface...
  • Page 47 M 01 Connector housing Place connector hous- ing on cylinder block and tighten slightly by hand with the three screws 1. Screw special tool onto cylinder block 2 Screw special tool onto connector housing 3 Nm); this aligns the fl ange surface.
  • Page 48 M 17 Flywheel Speed sensor DG6-S for fl ywheel Cylinder screw M 6x20 8.8 Caution! 9.5 Nm Remove speed sen- Sprocket sor before dismounting Mount in correct position at the fl ywheel and only approx. 250°C (beveled side install after mounting of the teeth must point in the the fl...
  • Page 49 M 10 Oil pump Rope seal Grease slightly for mounting Cylinder screw 2x spring pin 8x8 M 5x10 8.8 5.5 Nm Cover for oil pump Bulkhead Rotor set WDRI 40x62x7 Grease slightly for mounting and press in fl ush with housing 8x cylinder screw M 6x20 8.8 11 Nm...
  • Page 50 Z 30 Pulley Pulley crankshaft ø103 PK6 Special tool Bevel to the crankshaft 651 692 00 Remove after tighten- ing the pulley. Tension washer 16 Cylinder screw M 16x1,5x40 LH Left thread! 200 Nm...
  • Page 51 M 05 Piston and conrod Mount piston in cylinder block with help of the piston ring collet chuck 626 383 00 (heed notch for oil spray nozzle). Connect piston to con- rod, position grooves of the conrod bearing and notch for the oil spray nozzle on the piston are on the same side! Tighten conrod screws.
  • Page 52 M 10 Intake manifold Intake manifold complete 2 x cylinder screw Apply surface sealant M 8x16 8.8 Loctite 5910 here Glued in with Loctite 243 23 Nm...
  • Page 53 M 01 Oil sump Apply surface sealant Loctite 5910 here ac- cording to the red area 2nd screw connection (long hole) serves the alignment Combi screw M 6x13 8.8-A3D 1st screw connection 9.5 Nm (Ø6.2+0.1) serves the positioning Cu – sealing ring Cu –...
  • Page 54 M 36 Water pump 2 x spring pin 8x8 fi rst mount in crank- shaft Cylinder screw M 6x20 9.5 Nm 11x cylinder screw Phase encoder for M 6x20 cam shaft 9.5 Nm...
  • Page 55 Place roller tappet on M 01 Roller tappet special tool 653 466 00 and insert into crank- case. Marking for radial align- ment Special tool 653 464 00 Insert guide pins with special tool 653 464 00 into crankcase. Ensure with a slight turning of the roller tap- pet that the guide pin is in the groove of the...
  • Page 56 M 07 Cylinder head Valve cone MK6 Plate spring Valve spring inlet/outlet Valve spring outlet Valve shaft seal Plate for valve spring Valve disk inlet Valve disk outlet Insert and remove valves with special tool 629 223 01.
  • Page 57 M 07 Cylinder head Choosing the right cylinder head seal engine H50 Gap 0.6...0.7 piston 0,6 mm 0,5 mm 0,4 mm projecting measurement of the piston Ü [mm] (average values from all cylinders) Determine piston protrusion with special tool 653 474 00 and select cylinder head seal according to table.
  • Page 58 M 07 Cylinder head Cylinder screw M 6x80 Tightening process Combi screw 11 - 14 M 12x130 9.5 Nm Tightening process 1 - 10 1st stage: 20+2 Nm 2ndstage: 75°+5° 3rdstage: 75°+5°...
  • Page 59 M 07 Rocker arm Rocker arm inlet com- Rocker arm bearing plete block with axle Rocker arm outlet com- Locking ring A 18x1 plete Locking ring A 18x1 as needed Adjusting ring 15x21x0.2 Adjusting ring 15x21x0.3 Play: 0.1 ... 0.2 mm...
  • Page 60 M 07 Rocker arm Hexagon nut VM 8 23 Nm Rocker arm bearing block complete with levers Basic setting tappet Push rod clearance: Turn the cylinder to be adjusted in the working cycle. Loosen the lock nut and turn adjusting screw in until the calotte of the ad- justing screw lies against the spherical head of the...
  • Page 61 M 08 Cylinder head cover Hexagon bolt M 6x20 -F- A3B Screw plug for oil fi ller 9.5 Nm with RK ring 26x35x3 tighten hand-tight Cylinder head cover Paper seal for the cylinder head cover...
  • Page 62 Z 05 Glow plugs Hexagon nut M 4 2 ±0.2 Nm Washer 4.3 Pencil glow plug GLP 2 11V apply high-temperature paste 10 - 15 Nm...
  • Page 63 M 07 Thermostat, temp. sensor Temperature sensor TS cooling water max. 25 Nm O-ring 58x2 Housing thermostat Washer 6.4 Hexagon bolt M 6x25 11 Nm...
  • Page 64 M 28 Exhaust manifold Gasket (installation position: the raised side of the bead must point towards the exhaust manifold) Hexagon nut VM 8 25+2 Nm Sealing ring Screw plug G 1/4 30 Nm...
  • Page 65 M 28 Turbocharger Hollow screw 6 S 20 Nm 2 x sealing ring A 10x13.5 2 x sealing ring A 12x15.5 Hollow screw M 12x1.5 30 Nm Pressure oil line Turbocharger Gasket for the turbo- charger (position for the crimping at will) 3 x hex nut VM8 25 Nm...
  • Page 66 M 30 Lifting device Lifting eye 2 x cylinder screw M 8x20 23 Nm...
  • Page 67 M 37 Exhaust gas return Note: To guarantee a tension- free assembly, the mixing nozzle, the AGR cooler and the housing Gasket with bracket must fi rst be pre-mounted with- Mixing nozzle out tightening and then tightened in the speci- fi...
  • Page 68 M 37 Exhaust gas return 2 x gasket AGR cooler Heed installation posi- 2 x hexagon nut tion (marking)! VM 8 Housing 4 x cylinder screw M 8x25 A3C Gasket Bracket 4 x cylinder screw M 8x20 A3C...
  • Page 69 M 37 Exhaust gas return Tightening sequence: Position 1: 2 x hexagon nut VM 8 23 Nm Position 2: 2 x cylinder screw M 8x25 23 Nm Position 3: 2 x cylinder screw M 8x25 23 Nm Position 4: 2 x hexagon bolt M 10x70 46 Nm Position 5:...
  • Page 70 M 37 Exhaust gas return 4 x cylinder screw M 5x12 5.5 Nm Shaped hose piece 16x4.5 AGR valve 2 x hose clamp 12x22x9 2 x hexagon bolt M 6x16 9.5 Nm O-ring 8x2 Shaped hose piece 22x4.5 2 x hose clamp 20x32x13...
  • Page 71 M 37 Exhaust gas return Hose clamp with wave spring Shaped hose piece 45 x 5 Hose clamp with wave spring Cylinder screw M 5x16 5.5 Nm Washer 5.3 Pressure-temp. sensor DS-S3-TF for charge air Sensor holder...
  • Page 72 M 14 Injection system General instructions: All work on the injection system may only be done in the voltage and pressure-free state (disconnect battery). During all work on the injection system, cleanliness must be heeded in order to avoid the entry of particles into the injection system or the engine. After every loosening of a pressure tube, it must be replaced! Mounting of injectors on the engine Remove the protective caps only right before mounting.
  • Page 73 M 14 Injection system Fuel return line: max. number of plug assembly/removal (plugging in; locking; unlocking; removing the plug from the counter piece): 10x If during the removal of the plug connectors the O-ring on them is damaged, then the entire return line must be replaced. Before re-mounting of the plug connectors, it must be ensured that the counter pieces are not soiled or corroded.
  • Page 74 M 14 Injection system Before the installation or View A removal of the high-pres- sure pump, the crank- shaft must be turned into the position "CP4" (marking visible through inspection hole in the connection housing). The marking on the high- pressure pump is now in the position shown.
  • Page 75 M 14 Injection system Fuel line (mount on the return connection before installation of the high- pressure pump) High-pressure pump 3 x hexagon bolt with fl ange M 8x30 23 Nm...
  • Page 76 M 14 Injection system 2 x cylinder screw Fuel line M 8x20 23 Nm Washer 8.1x20x3 Hexagon nut High-pressure rail Fuel pressure tube 10 Nm + 60°(rail side) 15 Nm + 60°(pump 2 x hexagon bolt with side) fl ange M 8x30 23 Nm...
  • Page 77 M 14 Injection system Fuel return line Fuel pressure tube Cylinder 3+4 10 Nm + 60° CR injector Hexagon nut M 8 23 Nm Fuel pressure tube Bushing for injector Cylinder 1+2 10 Nm + 60° Clamping claw...
  • Page 78 M 31 Crankcase ventilation Provent 100 with exchangeable oil sepa- rator Shaped hose piece 2 x hexagon bolt with fl ange M 8x30 23 Nm 2 x wire hose clamp ID 23x1 Shaped hose piece 2 x wire hose clamp ID 18x1...
  • Page 79 4. Tables 3 - 4H50 / 05.2016...

  • Page 80: Screw Tightening Torque

    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 81 2±0.2 Nm...
  • Page 83 Montagehinweis 05674601 DPF chassisfest H50TICD Assembly advice 05674601 DPF chassis mounted H50 TICD...
  • Page 84 Montageanleitung DPF chassisfest 05674600 Historie Version Datum Verfasser Änderungen 05.03.2019 Hahn Alexander ÄM H19/031-1 15.07.2019 Hahn Alexander Update Inhaltsverzeichnis Deutsch ............................2 Englisch ............................14 1/28 Motorenfabrik Hatz GmbH & Co. KG...
  • Page 85 Montageanleitung DPF chassisfest 05674600 CAUTION Danger of cutting! Sharp edges on the diesel particulate filter. • Wear personal protective equipment (cut-resistant gloves). DANGER Danger of fire from hot exhaust gas system. The exhaust gas system and, in particular, the diesel particulate filter can become very hot.
  • Page 86 Montageanleitung DPF chassisfest 05674600 Overview/dimensions: removed diesel particulate filter (chassis) active premium Dimensions Exhaust inlet Inside Ø55.60mm Exhaust outlet Outside Ø55mm Inlet/outlet position correction The outlet of the chassis-mounted DPF can be rotated to any position. Inlet V-band clamp Because the leak tightness of the system is no longer ensured after the position of the inlet is corrected, it is prohibited to perform a position correction here.
  • Page 87 Montageanleitung DPF chassisfest 05674600 If a position correction is made, the following steps must be performed. Step Description Tighten V-clamp to 12 ±1Nm. Gently tap V-clamp with a light soft face hammer, from the places shown below. Re-Tighten V-clamp to 12 ±1Nm. Motorenfabrik Hatz GmbH &...
  • Page 88 Montageanleitung DPF chassisfest 05674600 Installation of the temperature sensors Step Description Coat the temperature sensor threads with Castrol Optimol TA and screw them into the two provided holes. Tightening torque: 45 ±5Nm. If using a pre-catalytic converter, see page 7 "Pre-catalytic converter". Installation of the DPF holder + cable holder Step Description...
  • Page 89 Montageanleitung DPF chassisfest 05674600 Installation of the pressure pipes/pressure sensor Step Description Attach the pressure sensor to the bracket using the cyl. screw M6x20. The temperature sensor plugs can be mounted on the bracket. Two threaded mounting positions are found on both the exhaust gas inlet and exhaust gas outlet.
  • Page 90 Montageanleitung DPF chassisfest 05674600 Coat the thread of the pressure pipes with Castrol Optimol TA and screw into the two threads facing up. Tightening torque: 45 ±5Nm. If you use your own pressure pipes, they must be at least 200mm long. To assemble the pressure pipe a clamping screw (056475XX) can be used, this can be obtained from Hatz.
  • Page 91 Montageanleitung DPF chassisfest 05674600 Connect the pressure sensor and the two pressure pipes to the 1000 mm hose and the 4 hose clamps. The hose must be divided to the desired lengths. Total length (pressure tube + hose): • Minimal 300mm (200mm pressure tube + 100mm hose) •...
  • Page 92 Montageanleitung DPF chassisfest 05674600 • The pipes must be fully insulated, for which an insulating tape is available from Hatz. This insulating tape must be wrapped so it overlaps in two layers. If an insulating tape from a different source is used, it must have the following properties: Stable at continuous temperature 450°C, short-term 550°C –...
  • Page 93 Montageanleitung DPF chassisfest 05674600 Pre-catalytic converter To prevent the diesel oxidation catalyst (DOC) from clogging, a pre-catalytic converter is used for low load/weak load applications. For chassis mounted DPFs, the pre-catalytic converter is available as an option from Hatz and must be mounted as close as possible to the DOC/DPF in the exhaust gas pipe.
  • Page 94 Montageanleitung DPF chassisfest 05674600 • Prevent water from entering into the exhaust gas pipe (e.g. flaps or suitable pipe elbows at the end). • When installing an exhaust gas pipe, an elastic intermediate part must be installed along the exhaust gas pipe to absorb the engine movement. The compensator must be attached close to the pivot point of the elastic bearing.
  • Page 95 Montageanleitung DPF chassisfest 05674600 Wiring harness transfer point The transfer point for the chassis-mounted DPF cable is at the plug retaining plate (see figure). From this point onward, a cable length of approx. 1.2m is present. In addition, a 2m extension wiring harness is available from Hatz.
  • Page 96 Montageanleitung DPF chassisfest 05674600 Cabling for auxiliary heater of DPF chassis (Active Premium) 12V Step Description Screw the positive cables for the auxiliary heaters GK1 and GK2 (Ø6 mm²) onto the glow plug. Screw the ground line onto the ground connection plate. Cable lug Washer 504127XX...
  • Page 97 Montageanleitung DPF chassisfest 05674600 Connect cables GK1 and GK2 (Ø6mm²) with the "Power module" board of the particulate filter. Cabling for auxiliary heater of DPF chassis (Active Premium) 24V Step Description Screw the positive cable of the auxiliary heater onto GK1 and the ground cable onto GK2 (Ø6 mm²).
  • Page 98 Montageanleitung DPF chassisfest 05674600 Attach the cables of the auxiliary heater to the cable holder using cable ties. The cables must be mechanically fastened after no more than 250mm to protect them against pulling, pushing and vibration forces (strain relief). Connect cable GK1 (Ø6mm²) to the "Power module"...

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