Page 1
4H50TIC
www.HATZ-DIESEL.com
Hatz Diesel
CREATING POWER SOLUTIONS.
OPERATOR’S MANUAL
Diesel engine
00000000 443366 000044 0000 -- 0077..22001144 -- 00..11
Printed in Germany
EN
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.
Page 2
4H50TIC Table of contents
Table of contents
1 Notices ............................................................................................................. 5
2 General information ........................................................................................ 6
3 Safety ............................................................................................................... 7
3.1 General information .......................................................................................... 7
3.1.1 Intended use and foreseeable misuse .............................................................. 7
3.1.2 Machine user or machine manufacturer obligations ......................................... 8
3.1.3 Representation of safety notes ......................................................................... 9
3.1.4 Meaning of safety symbols ............................................................................... 10
3.2 Safety notes ...................................................................................................... 11
3.2.1 Operational safety ............................................................................................. 11
3.2.2 Machine-specific safety instructions for operation ............................................ 14
3.2.3 Machine-specific safety instructions for maintenance work .............................. 15
3.2.4 Electrical equipment .......................................................................................... 18
3.3 Labels ............................................................................................................... 19
4 Technical data ................................................................................................. 20
4.1 Engine information and filling quantities ........................................................... 20
4.2 Engine type plate .............................................................................................. 21
4.3 Engine oil .......................................................................................................... 22
4.4 Coolant .............................................................................................................. 23
4.5 Fuel ................................................................................................................... 26
5 Engine design ................................................................................................. 28
5.1 Overview ........................................................................................................... 28
6 Transport, assembly and commissioning .................................................... 31
6.1 Transport - Engine with 2 lifting eyes ................................................................ 31
6.2 Assembly instructions ....................................................................................... 32
6.3 Preparations for commissioning ........................................................................ 33
6.4 Filling engine oil ................................................................................................ 33
6.5 Filling the cooling system .................................................................................. 35
7 Operation and use .......................................................................................... 38
7.1 Safety notes ...................................................................................................... 38
7.2 Performing tests ................................................................................................ 38
7.3 Starting the engine ............................................................................................ 39
7.4 Starting the engine for the first time/after a filter change .................................. 42
7.5 Switching off the engine .................................................................................... 45
7.6 Checking the oil level and adding oil if necessary ............................................ 47
7.7 Refueling ........................................................................................................... 49
8 Maintenance .................................................................................................... 51
8.1 General maintenance instructions .................................................................... 51
8.2 Maintenance work ............................................................................................. 52
HATZ
Operator's Manual 3
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Table of contents 4H50TIC
8.2.1 Maintenance plan .............................................................................................. 52
8.2.2 Checking the intake area of the combustion air ................................................ 54
8.2.3 Checking the radiator fins for dirt accumulation ................................................ 55
8.2.4 Checking the cooling system ............................................................................ 57
8.2.5 Changing the engine oil and oil filter ................................................................. 59
8.2.6 Cleaning the radiator fins .................................................................................. 64
8.2.7 Tensioning the poly v belt ................................................................................. 67
8.2.8 Replacing the poly v belts ................................................................................. 69
8.2.9 Changing the oil separator of the crankcase ventilation ................................... 71
8.2.10 Checking the screw connections ...................................................................... 72
8.2.11 Draining the water separator ............................................................................. 73
8.2.12 Changing the fuel prefilter ................................................................................. 74
8.2.13 Changing the fuel fine filter ............................................................................... 77
8.2.14 Servicing the air filter (optional) ........................................................................ 80
8.2.15 Changing coolant .............................................................................................. 82
9 Faults ............................................................................................................... 86
9.1 Fault table ......................................................................................................... 86
10 Storage and disposal ...................................................................................... 95
10.1 Storing the machine .......................................................................................... 95
10.2 Disposing of the machine .................................................................................. 95
11 Installation declaration ................................................................................... 97
4 Operator's Manual
HATZ
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4H50TIC Notices
1 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. The same conditions apply to distribution of
the Operator's Manual to third parties in digital form.
Original Operator's Manual
This Operator's Manual was translated into multiple languages.
The German version is the original Operator's Manual. All other language
versions are translations of the original Operator's Manual.
HATZ
Operator's Manual 5
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General information 4H50TIC
2 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.
Before commissioning, during operation and before maintenance work is begun on the machine, read the Operator's Manual carefully and keep it close
by for ready access.
Machine
This Operator's Manual describes the following machine.
Machine name HATZ diesel engine
Type number 4H50TIC
Customer service
Have service work performed by qualified technicians only. We recommend
that you work with one of the more than 500 HATZ service stations.Trained
specialists there will repair your machine with Hatz original spare parts and
with HATZ tools. The global HATZ service network is at your disposal to advise you and supply you with spare parts. For the address of the Hatz serv-
ice station nearest you, please see the directory enclosed or visit the internet at: www.hatz-diesel.com
Problems may occur if unsuitable spare parts are installed. We cannot accept responsibility for damage and secondary damage that result from this.
We therefore recommend the use of Hatz original spare parts. These parts
are manufactured according to strict Hatz specifications and achieve maximum operational reliability through their perfect fit and functionality. The order number can be found in the enclosed spare parts list or on the internet
at: www.hatz-diesel.com
Exclusion of liability
The manufacturer cannot be held responsible for personal injury, damage to
property, or damage to the machine itself caused by improper use, foreseeable misuse, or failure to follow or adequately follow the safety measures and
procedures described in this Operator's Manual. This also applies to
changes made to the machine and use of unsuitable spare parts.
Modifications, which serve the technical improvements, are reserved.
6 Operator's Manual
HATZ
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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.
3.1.1 Intended use and foreseeable misuse
Intended use
The machine described in this Operator's Manual fulfills the following functions:
▪ Diesel engine intended for installation in a machine or for assembly with
other machines to form a machine. See chapter 11 Installation declaration,
page 97.
This engine is intended exclusively for the purpose specified and tested by
the manufacturer of the machine into which the engine is installed.
Any other use is not intended and therefore not permitted. Violations compromise the safety of the personnel working with the machine. Responsibility
is not accepted by Motorenfabrik HATZ for damage resulting from this situation.
The operational safety of the machine is only guaranteed if it is used as intended.
Use according to the intended purpose also includes observance of the instructions in this Operator's Manual.
HATZ
Foreseeable misuse
The following is considered to be foreseeable misuse:
▪ Any use that varies from or extends beyond the uses specified above.
▪ Failure to comply with the instructions in this Operator's Manual.
▪ Failure to comply with the safety instructions.
▪ Failure to immediately eliminate malfunctions that impact safety before
continuing work with the machine (working with the machine when it is not
in perfect condition, either functionally or in terms of safety).
▪ Failure to perform the necessary inspection and maintenance work.
▪ Any unauthorized modification of or removal of safety equipment.
▪ Use of spare parts and accessories that are unsuitable or have not been
approved by HATZ.
▪ Operation in flammable or hazardous environments.
▪ Operation in closed-off or poorly ventilated rooms.
Operator's Manual 7
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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 3.2.3 Machinespecific safety instructions for maintenance work, page 15 as well as in the
further contents of the manual, directly in front of the descriptions or operating instructions concerned.
3.1.2 Machine user or machine manufacturer obligations
Machine manufacturer obligations
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine. These assembly instructions contain important information on how to safely install the engine and are available at your nearest HATZ service station.
It is prohibited to start the engine before it is fully installed.
In addition, please note that it is prohibited to start up the machine before it
has been determined that the machine into which this engine is installed fulfills all safety-related requirements and legal regulations.
User obligations
The user is obligated to only operate the machine while it is in perfect condition. The user must check the condition of the machine before using it and
ensure that any defects are eliminated before it is taken into service. Running the machine while identified defects exist is not permitted. The user
must also ensure that the information contained in the Operator's Manual
has been read and understood.
Obligations of the operating and maintenance personnel
Personnel assigned with operating and maintaining the machine must have
read and understood the Operator's Manual or must possess the qualifications necessary for working with this equipment, acquired in training/instructional courses. No one may work with the machine without the necessary
qualifications, even if for just a brief period.
The operating personnel must not be under the influence of drugs, medication or alcohol.
All work performed on the machine must be in compliance with the information provided in the Operator's Manual.
8 Operator's Manual
HATZ
Page 8
DANGER
WARNING
CAUTION
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.
These risks are identified in this manual by means of safety notes.
The safety notes precede the related description or operating step.
Structure of the safety notes
The safety notes consist of:
▪ Warning symbol
▪ Signal word
▪ Description of danger
▪ Possible consequences
▪ Preventative measures
General danger symbol
HATZ
Signal words
The general danger symbol is used to identify the danger of personal injury.
Signal words identify the magnitude of the risk and the seriousness of the
possible injuries:
Danger symbol/
Meaning
signal word
This signal word is used to indicate imminently
dangerous situations which, if not avoided, will
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to serious injury or death.
This signal word is used to indicate potentially
dangerous situations which, if not avoided, may
lead to minor or moderate injury.
Operator's Manual 9
Page 9
CAUTION
NOTICE
Safety 4H50TIC
Danger symbol/
signal word
3.1.4 Meaning of safety symbols
Explanation of symbols
The following table describes the meanings of the safety symbols used in
this Operator's Manual.
Symbol Meaning
Smoking, fire and open flames are prohibited.
Warning of personal injury!
Warning of hot surfaces!
Meaning
This signal word, without a danger symbol, is
used to indicate the risk of property damage.
This signal word indicates additional useful information, such as operating tips and cross references.
Warning of flammable substances!
Warning of explosive substances!
Warning of toxic engine exhaust!
Warning of corrosive substances!
10 Operator's Manual
HATZ
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i
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.
3.2 Safety notes
3.2.1 Operational safety
HATZ
Introduction
This chapter contains all of the important safety instructions for personal protection and for safe and reliable operation. Additional, task-related safety instructions can be found at the beginning of each chapter.
DANGER
Danger to life, danger of injury, or danger of property damage due to failure to comply with the Operator's Manual and
the safety instructions contained therein.
▪ As the user of the machine, you must ensure that all people
working on the machine are familiar with the contents of this
Operator's Manual.
▪ Before working on the machine, read this Operator's Manual
carefully, paying special attention to the safety notes.
▪ Fulfill all required safety conditions before working on the
machine.
▪ Follow all general safety instructions as well as the specific
task-related safety instructions contained in the individual
chapters.
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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 asso-
ciations.
▪ Comply with the regulations concerning the minimum safety and health re-
quirements for the use of work equipment by workers at work.
▪ In addition, local safety, accident prevention and environmental regula-
tions also apply when operating the machine.
Personal protective equipment
During operation and maintenance of the machine, personal protective
equipment must be available and must be used if necessary. The required
personal protective equipment is specified in the description of the operating
steps.
Personal protective
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
Safety goggles
(with side protection)
Working clothes Wear close-fitting clothing. How-
12 Operator's Manual
against injury, e.g. from battery
acid.
Safety goggles protect the eyes
from flying objects (e.g. dust
particles, spraying liquids,
spraying acid).
ever, it must not restrict the
wearer's freedom of movement.
HATZ
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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.
Maintenance work
Maintenance work that goes beyond the scope described in this manual
must only be performed by qualified technicians (see the chapter 2 General
information, page 6).
Independent maintenance work and constructional changes to the machine,
especially to the safety equipment, are not permitted.
Safety equipment
Safety equipment must not be modified and must not be rendered ineffective
during normal operation.
General safety instructions
DANGER
Danger to life and danger of injury due to failure to follow
the warnings on the machine and in the Operator's Manual.
▪ Heed the warnings on the machine and in the Operator's
Manual.
HATZ
WARNING
Danger of injury and danger of incorrect operation due to
inadequate personnel qualifications.
▪ The personnel must have read and understood this Opera-
tor's Manual or must possess the qualifications necessary
for working with this equipment, acquired in training/instructional courses.
▪ Only qualified personnel are permitted to operate and main-
tain this machine.
▪ Failure to comply will cause the warranty to become void.
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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 availa-
ble. Contact properly trained personnel if necessary.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist (see the chapter 6.1 Trans-
port - Engine with 2 lifting eyes, page 31).
3.2.2 Machine-specific safety instructions for operation
Introduction
The machine can pose residual risks during operation. To eliminate these
risks, all persons working on the machine must follow the general and machine-specific safety instructions.
If you have an engine that is not yet installed in a machine, it is imperative
that you follow the Assembly Instructions for HATZ Diesel Engines before installing the engine.
These assembly instructions contain important information on safe installation.
If the engine is installed in a machine or assembled with other machines to
form a machine, it is prohibited to start the engine before it has been determined that the newly created machine fulfills all safety-related requirements
and applicable legal regulations.
Safe operation
▪ Before switching on the machine, ensure that no one can be injured when
the machine is started up.
▪ During machine operation, ensure that unauthorized persons do not have
access to the area in which the machine has an impact.
▪ Parts of the exhaust gas system and the surface of the engine become hot
during operation. Risk of injury from touching hot parts! Let the engine cool
before maintenance.
▪ Do not refuel during operation.
14 Operator's Manual
HATZ
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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.
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
3.2.3 Machine-specific safety instructions for maintenance work
HATZ
Introduction
The machine can pose residual risks during maintenance. To eliminate
these risks, all persons working on the machine must follow the general and
machine-specific safety instructions.
Maintenance intervals
▪ Strictly adhere to the maintenance intervals.
▪ Check the safety equipment regularly to ensure it is in good condition and
functioning properly.
▪ Check connections, cables and fasteners regularly to ensure they are in
good condition.
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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 gen-
uine HATZ original spare parts (see the chapter 2 General information,
page 6).
▪ When disposing of parts that can no longer be used, do so in accordance
with local environmental regulations or send them to a recycling center.
Measures following maintenance and troubleshooting
▪ Securely reconnect loose electrical connections; check that the electrical
components and equipment are functioning properly.
▪ Check the entire machine for foreign bodies; remove any foreign bodies.
Safety instructions for maintenance work
DANGER
Danger of explosion from flammable cleaning agents.
Cleaning with benzene is an explosion hazard. It is highly flammable, can become electrostatically charged and can generate
an explosive gas-air mixture.
▪ Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
DANGER
Fire hazard from spontaneous combustion.
Cleaning materials soaked with cold cleaner may produce heat
together with atmospheric oxygen and combust spontaneously.
▪ Collect cleaning materials soaked with cold cleaner only in
fire-proof, tightly sealed containers.
▪ Do not dispose of cold cleaner residues and used cleaning
materials with domestic waste, rather only in accordance
with manufacturer instructions.
▪ Comply with the instructions for preventing fire on the safety
data sheet for the cold cleaner.
16 Operator's Manual
HATZ
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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.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
HATZ
Operator's Manual 17
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Safety 4H50TIC
3.2.4 Electrical equipment
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 termi-
nals.
▪ When installing the battery, first connect the positive cable
and then the negative cable.
▪ When removing the battery, first disconnect the negative
cable and then the positive cable.
▪ It is imperative that you prevent short circuits and mass con-
tact of current-carrying cables.
▪ If faults occur, check the cable connections for good con-
tact.
Safety notes
DANGER
Danger of explosion from flammable substances.
There is a danger of explosion from flammable gases.
▪ Keep batteries away from open flames and incendiary
sparks.
▪ Do not smoke when working with batteries.
CAUTION
Danger of chemical burns
Chemical burns can occur when using batteries for the electrical
operation.
▪ Protect your eyes, skin, and clothing from corrosive battery
acid.
▪ Immediately rinse areas affected by splashed acid with clear
water and consult a physician if necessary.
18 Operator's Manual
HATZ
Page 18
BIO
DIESEL
052 356 02
0000 053 657 02
4H50TIC Safety
3.3 Labels
Warning labels and information signs on the engine
NOTICE
▪ The necessary wiring diagrams are included with the ma-
chine if it is equipped with electrical equipment. Additional
wiring diagrams can be requested when needed.
▪ We cannot be held liable for electrical equipment that is not
designed according to HATZ wiring diagrams.
▪ Promptly replace faulty indicator lamps.
▪ Do not pull out the starting key during operation.
▪ Do not disconnect the battery while the machine is running. Resulting volt-
age peaks could destroy the electronic components.
▪ When cleaning, do no spray the electrical equipment components with a
water jet or high pressure cleaner.
▪ When performing welding work on the machine, disconnect the battery
and place the ground clamp of the welding equipment as close as possible
to the welding area. Disconnect the plug-in connection to the voltage regulator.
Label Meaning
Refuel with diesel fuel only. For the
specification, see the chapter 4.5
Fuel, page 26
Do not use bio diesel.
The engine may only be operated
with fuel that is "EXTREMELY LOW
IN SULFUR OR SULFUR-FREE".
The fuel label is located close to the
fuel cap. If there is no fuel tank installed on the engine, the label must
be applied permanently close to the
fuel filler opening.
HATZ
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Technical data 4H50TIC
4 Technical data
4.1 Engine information and filling quantities
Type 4H50TIC
Type
Combustion system
Injection system Bosch common rail
Number of cylinders
Bore/stroke mm 84 / 88
Displacement cm
3
Engine oil capacity Approx.
ltr.
Difference between the
"max." and "min."
marks
Approx.
ltr.
Engine oil consumption
(after running-in period)
Max. 0.5 % of fuel consumption, pertaining to full load
Engine oil pressure 2.5 bar to 4.5 bar
Coolant quantity Approx.
ltr.
Sense of rotation
Tappet clearance Automatic valve lash adjustment with hydraulic
Max. perm. inclination
30° 2) (with HATZ standard radiator)
during continuous operation in every direction
Weight (without operating
Approx.kg226 (with HATZ standard radiator and catalytic
fluids)
Battery capacity Max. 12 V – 110 Ah / 450 A according to DIN
Liquid-cooled four stroke diesel engine
Direct injection, turbocharger with charge air cool-
ing, cooled exhaust-gas recirculation
4
1,952
1)
7.0
1)
1.0
12.5 (HATZ standard radiator with external expansion tank)
13.2 (HATZ OpenPowerUnit radiator with integrat-
ed expansion tank)
When viewing flywheel: left
valve tappets
20° 2) (with HATZ OpenPowerUnit radiator)
converter)
260 (with HATZ OpenPowerUnit radiator and cata-
lytic converter)
24 V – 66 Ah / 300 A according to DIN
20 Operator's Manual
HATZ
Page 20
120R-xxxxxx*xx
24R-xxxxxx
EMISSION CONTROL INFORMATION
MOTORENFABRIK HATZ KG ¬ D-94099 RUHSTORF
GMBH
+CO
Model: 4H50TIC – 162J
S/N: 1361014000001 Build: 03/2014
Power: 36.4kW @ 1800 RPM Constant
Displ: 1.95L
Eng.Fam: FHZXL1.95C50
Emission Control System: DDI, DOC, EGR, ECM, TC, CAC
Power Category: 19≤kW<37
ULTRA LOW SULFUR DIESEL FUEL ONLY.
THIS ENGINE COMPLIES WITH U.S. EPA AND CALIFORNIA REGULATIONS
FOR THE MY2015 YEAR NONROAD DIESEL ENGINES.
Use in Constant-Speed Applications only.
EU-Type: e1*97/68KA*2012/46*0801*00 (IIIA)
www.hatz-diesel.com
187_44_C_3B
120R xxxxxx*xx
24R xxxxxx
E
1
8
9
4H50TIC Technical data
1)
These values are approximations only. The max. mark on the dipstick is
decisive in any case (see the chapter 7.6 Checking the oil level and adding
oil if necessary, page 47).
2)
Exceeding these limit values can cause engine damage.
4.2 Engine type plate
The engine type plate is located on the crankcase and contains the following
engine information:
1 Model designation of the engine
2 Engine serial number
3 Serial rating (kW) at nominal speed (rpm)
4 Displacement (liters)
5 Information for US emission certification (EPA/CARB)
6 EU type approval
7 EU country of origin (Germany)
HATZ
8 Model year (month/year)
9 Bar code (engine serial number)
The following data must always be specified for requests and spare part orders
1 Model designation
2 Engine serial number
Operator's Manual 21
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Technical data 4H50TIC
4.3 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.
Unsuitable engine oil diminishes the functionality and service life
of the catalytic converter and/or particulate filter.
Only use engine oil that fulfills the specifications stipulated
above. In principle, engine oils with low ash (low SAPS) are recommended.
Engines without catalytic converter and without particulate filter
▪ ACEA E6, E7 or E9
▪ ACEA C1, C2, C3 or C4
▪ API CJ-4 or CI-4
Oil viscosity
22 Operator's Manual
HATZ
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4H50TIC Technical data
Select the recommended viscosity depending on the ambient temperature in
which the engine will be operated.
4.4 Coolant
Introduction
Liquid-cooled engines require a coolant specified by HATZ for engine cooling.
Coolant is prepared in accordance with manufacturer's instructions, please
comply with the information on the packaging label.
Radiator protection fluids give effective protection against corrosion and
freezing. Additionally, the coolant boiling point is significantly raised and deposits of lime in the cooling system are reduced.
Safety notes
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.
CAUTION
Danger of damage to health
Radiator protection fluids are harmful to health.
▪ Avoid contact to eyes and skin.
▪ Store only in the sealed original container and in a place in-
accessible for unauthorized persons.
▪ Comply with manufacturer's instructions.
HATZ
CAUTION
Danger of environmental damage from spilled coolant.
Coolant is water-polluting.
▪ Do no allow it to enter the ground water, water bodies, or
sewage system.
▪ Collect coolant and dispose of it in an environmentally com-
patible manner.
Operator's Manual 23
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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. The consequence may be damage to
the water pump, radiator, hoses, and gaskets.
▪ Before changing the product, flush the entire cooling system
(see the chapter 8.2.15 Changing coolant, page 82).
Approved radiator protection fluids
The following radiator protection fluids are approved by HATZ:
Manufacturer Product name
ARAL Aral Antifreeze Silikatfrei (silicate-free)
Arteco Havoline XLC (OF02), Havoline XLC+B
Auto-Teile-Ring Cartechnic Antifreeze CT 12 plus
BASF Glysantin® G30®, Glysantin® G40®
Belgin Madeni
LUBEX ANTIFREEZE G-12 PLUS
Yaglar Tic
BP BP Procool
Bucher MOTOREX COOLANT M4.0
BVG Blume Mofin Antifreeze M40 Extra
Castrol Radicool SF, Radicool Si OAT
CCI LLC C521, LLC L415
CHEMIA-
Glidex Extra Premium
BOMAR
Chevron Caltex Extended Life Coolant, Havoline XLC Concentrate,
Ursa ELC NF Concentrate
CLASSIC CLASSIC KOLDA UE G30, CLASSIC KOLDA UE G40
24 Operator's Manual
HATZ
Page 24
i
4H50TIC Technical data
Manufacturer Product name
Eurolub Radiator protection fluid D-30, PROCAR radiator protec-
tion 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
Krafft K-140 Energy - Plus
Kuttenkeuler Kuttenkeuler Antifreeze K 12 Plus
LUKOIL OMV coolant SF, OMV coolant SOT
Mitan Alpine C40, Alpine C12+
MOL-LUB EVOX Premium Concentrate
Müller Mineralöle
Neste Markkinointi
OAO Technoform
Old World Industries
Petrol Ofisi
Anonim Sirketi
Tedex Tedex Antifreeze OT LL
Total Total Glacelf Auto Supra
Valvoline Zerex G 30, Zerex G 40-91
G-ENERGY ANTIFREEZE SNF
Startol Top G 12 Plus
Neste Superjäähdytinneste XLC
Cool Stream Premium
Final Charge Global Coolant
PO EXTENDED LIFE coolant
HATZ
NOTICE
Prior approval from HATZ is needed when none of these radiator protection fluids is available or an own-product radiator protection fluid is to be used.
Operator's Manual 25
Page 25
i
Technical data 4H50TIC
Preparation of the coolant
▪ The radiator protection fluid must be prepared according to manufacturer's
instructions before pouring it into the cooling circuit. Comply with the information on the packaging label.
▪ If the radiator protection fluid has to be mixed with water, use only clean
water that is not too hard. Tap water with as low as possible content of
salt, minerals, and suspended matter is ideal. Distilled water is equally ideal.
The coolant mixture ratio is not to be below or exceed the following concentration:
Radiator protection
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. Therefore, serious engine damage may result from exceeding or dropping below the radiator protection fluid concentration.
Water Frost-resistant to ap-
fluid
min. 40 vol% 60 vol% -27 °C
max. 50 vol% 50 vol% -38 °C
prox.
NOTICE
As the corrosion and antifreeze concentration reduces with time,
carry out an annual check with a commercially available antifreeze tester. If the concentration is too low, change the coolant
independent of the service interval (see the chapter 8.2.15
Changing coolant, page 82).
4.5 Fuel
26 Operator's Manual
Fuel type
All types of diesel fuel that meet the minimum requirements of the following
specifications are suitable:
▪ Europe: EN 590
▪ UK: BS2869 A1/A2
▪ USA: ASTM D 975-09a 1-D or 2-D (engines without catalytic converter
and without particulate filter)
ASTM D 975-09a 1-D S15 or 2-D S15
HATZ
Page 26
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.
▪ 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).
HATZ
Operator's Manual 27
Page 27
4
32
5
5
6
7
8
9
10
11
12
13
14
15
16
17
1
Engine design 4H50TIC
5 Engine design
5.1 Overview
Intake side
28 Operator's Manual
HATZ
Page 28
4H50TIC 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
HATZ
Operator's Manual 29
Page 29
1
2
3
4
5
6
7
8
9
Engine design 4H50TIC
Exhaust side
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
30 Operator's Manual
HATZ
Page 30
4H50TIC Transport, assembly and commissioning
6 Transport, assembly and commissioning
6.1 Transport - Engine with 2 lifting eyes
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.
Safety notes
CAUTION
Only use lifting lugs for transporting the engine.
Do not use for lifting the entire machine.
CAUTION
Danger of injury from overloading the body.
Lifting the machine to transport it or to move it to another location can lead to injuries (of the back, for example).
▪ Only lift the machine with a hoist.
HATZ
NOTICE
Danger of environmental damage from leaking fluid.
If the machine is tilted, engine oil and fuel can run out.
▪ Only transport the machine in an upright position.
Operator's Manual 31
Page 31
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 lift-
ing eyes must be replaced and if necessary additional lifting points must
be used.
▪ When transporting the machine, follow the safety instructions.
▪ When transporting, follow the applicable safety and accident prevention
regulations of the trade associations.
▪ After delivery, check the machine for completeness and transport damage.
▪ Only transport the machine when it is switched off and has cooled down.
▪ If you have questions on transporting the machine, please contact your
nearest HATZ service station. For contact data, see the chapter 1 Im-
pressum, page 5 or www.hatz-diesel.com.
6.2 Assembly instructions
32 Operator's Manual
Assembly notes
HATZ diesel engines are efficient, robust and long-lived. Therefore, they are
usually installed in machines that are used for commercial purposes.
The machine manufacturer must follow the applicable regulations regarding
machine safety – the engine is a part of a machine.
Depending on the use and installation of the engine, it may be necessary for
the machine manufacturer and machine user to install safety equipment to
prevent inappropriate use. Note the following:
HATZ
Page 32
4H50TIC Transport, assembly and commissioning
▪ Parts of the exhaust gas system and the engine surface become hot dur-
ing operation and should not be touched until they cool down after the engine is switched off.
▪ Incorrect cable connections and incorrect operation of the electrical equip-
ment can lead to sparking and must be avoided.
▪ After the engine is installed in the machine, rotating parts must be protect-
ed against contact.
HATZ safety equipment is available for the belt drive of the cooling fan and
alternator.
▪ Comply with all notice and warning labels on the engine and keep them in
a legible condition. If a label should become detached or be difficult to
read, it must be replaced promptly. For this purpose, contact your nearest
HATZ service station.
▪ Any improper modification of the engine results in a loss of liability cover-
age for resulting damage.
Only regular maintenance, as specified in this Operator's Manual, will maintain the operating readiness of the engine.
The assembly instructions contain important information on how to safely assemble the engine. They are available from any Hatz service station.
If you have any questions, please contact your nearest HATZ service sta-
tion before commissioning the engine.
6.3 Preparations for commissioning
▪ Check the delivered parts for completeness, damage, and other noticeable
issues.
▪ Ensure that the setup location is adequately ventilated.
Danger 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.
6.4 Filling engine oil
HATZ
Engines are normally delivered without an engine oil filling.
DANGER
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
Operator's Manual 33
Page 33
Transport, assembly and commissioning 4H50TIC
CAUTION
Danger of later engine damage.
▪ Operating the engine with an oil level below the min. mark
Safety note
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
Step Activity
1 Pull out the dipstick (1) and clean it.
34 Operator's Manual
HATZ
Page 34
4H50TIC 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.
6.5 Filling the cooling system
CAUTION
Danger of burns.
There is a danger of burns when working on a hot cooling system. The cooling system is pressurized.
▪ Let the engine cool.
▪ Wear safety gloves.
Safety notes
CAUTION
Danger of later engine damage.
▪ Operating the engine with a coolant level below the MIN.
mark can lead to engine damage.
▪ When checking the coolant level, the engine must be hori-
zontal and be switched off.
HATZ
Operator's Manual 35
Page 35
MAX
MIN
MAX
MIN
12
43
Transport, assembly and commissioning 4H50TIC
Overview
1 Expansion tank for coolant
2 Sealing cap
3 MAX - Maximum coolant level
4 MIN - Minimum coolant level
Procedure
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.
3 Tighten the sealing cap (2) by hand all the way.
4 Start the engine (see the chapter 7 Operation and use,
page 38).
5 Warm up the engine until the coolant has reached a tempera-
ture of approx. 85°C. Above this temperature the coolant is
pumped through the entire cooling system and forces out remaining air bubbles.
6 Switch off the engine and let it cool down completely (see the
chapter 7 Operation and use, page 38).
7 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.
36 Operator's Manual
HATZ
Page 36
4H50TIC 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).
HATZ
Operator's Manual 37
Page 37
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 lo-
calized 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.
▪ Define the responsibilities of the personnel taking the ma-
chine into service.
▪ Replace faulty machine parts immediately.
▪ Check the installation conditions when the machine is first
taken into service and after the machine has been inactive
for a lengthy period.
CAUTION
Danger of engine damage from low load operation.
Operating the engine at no load or at very low load for an extended period can impair the running characteristics of the engine.
▪ Make sure that the engine load is at least 15 %.
▪ Before switching off the engine following low load operation,
briefly operate it at a considerably higher load.
7.2 Performing tests
38 Operator's Manual
Before starting
Before starting the engine, several tests need to be performed to ensure the
machine is working properly.
HATZ
Page 38
4H50TIC Operation and use
Procedure
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 chap-
ter 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 nec-
essary, page 47).
5 There is a sufficient amount of coolant in the expansion tank
(see the chapter 8.2.4 Checking the cooling system, page 57).
6 Radiator and radiator hoses are free from leaks (see the chapter
8.2.4 Checking the cooling system, page 57).
7 No persons are located in the danger zone of the engine or ma-
chine.
8 All safety equipment is in place.
7.3 Starting the engine
Safety notes
DANGER
HATZ
Danger to life from inhaling exhaust gases.
Toxic engine exhaust gases can lead to loss of consciousness
and even death in closed-off and poorly ventilated rooms.
▪ Never operate the machine in closed-off or poorly ventilated
rooms.
▪ Do not breathe in the exhaust gases.
CAUTION
Danger of engine damage from the use of starting fluid.
▪ The use of engine damage from the use of starting fluid can
lead to uncontrolled ignition.
▪ Engine damage from uncontrolled ignitions.
▪ Never use starting fluid.
Operator's Manual 39
Page 39
4
II
I
6
7
8
9
10
11
5
0
1
3
2
Operation and use 4H50TIC
NOTICE
See also starting instructions in the documentation for the complete machine.
Overview — HATZ instrument boxes
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
40 Operator's Manual
11 Operating display
Ignition lock
0 Off
I Operation
II Starting
HATZ
Page 40
i
i
4H50TIC Operation and use
Procedure
Step Activity
1 Remove the protective cap (4) from the ignition lock.
2 Insert the starting key all the way and turn to position "I".
3 Turn the starting key to position "II".
4 As soon as the engine is running, release the starting key.
NOTICE
▪ After approx. 20 seconds the start procedure cuts off auto-
matically 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.
▪ The anti repeat device in the ignition lock makes it impossi-
ble for the starter to engage while the engine is running and
become damaged.
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.
▪ The starting key springs back to position "I" and remains in
this position during operation.
▪ The charge control (10) and oil pressure display (9) go out.
▪ The operating display (11) lights up.
HATZ
NOTICE
▪ In case of irregularities, switch off the engine immediately.
▪ Identify the fault and eliminate it.
▪ For details of troubleshooting, see the chapter 9.1 Fault ta-
ble, page 86.
Operator's Manual 41
Page 41
4
II
I
6
7
8
9
10
11
5
0
1
3
2
Operation and use 4H50TIC
7.4 Starting the engine for the first time/after a filter change
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 notes
CAUTION
Danger of engine damage from the use of starting fluid.
▪ The use of engine damage from the use of starting fluid can
lead to uncontrolled ignition.
▪ Engine damage from uncontrolled ignitions.
▪ Never use starting fluid.
NOTICE
See also starting instructions in the documentation for the complete machine.
Overview — HATZ instrument boxes
42 Operator's Manual
HATZ
Page 42
i
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
HATZ
Procedure
Step Activity
1 Remove the protective cap (4) from the ignition lock.
NOTICE
▪ After approx. 20 seconds the start procedure cuts off auto-
matically 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.
▪ The anti repeat device in the ignition lock makes it impossi-
ble for the starter to engage while the engine is running and
become damaged.
Operator's Manual 43
Page 43
i
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.
3 Leave the starting key at position "I" until you hear the fuel feed
pump switches off (approx. 30 seconds).
4 Turn the starting key to position "II". The start procedure takes
longer than normal as air is still in the fuel system.
5 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 (10) and oil pressure display (9) go out.
▪ The operating display (11) lights up.
NOTE: There is air in the fuel system when starting the engine
for the first time/after a filter change. The engine therefore starts
in the emergency program (reduced power and speed).
6 Run the engine for approx. 2 minutes in the emergency program
to make sure there is no more air in the fuel system.
7 Switch off the engine and leave it switched off for at least 2 mi-
nutes. At the next start the engine again runs in the normal program.
44 Operator's Manual
NOTICE
▪ In case of irregularities, switch off the engine immediately.
▪ Identify the fault and eliminate it.
▪ For details of troubleshooting, see the chapter 9.1 Fault ta-
ble, page 86.
HATZ
Page 44
i
4H50TIC Operation and use
7.5 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.
▪ To prevent damage due to overheating, cool down the en-
gine before switching it off by running it for approx. 5 minutes at a reduced speed and load.
▪ When the machine is switched off, always turn the starting
key to position "0" or else the battery may become fully discharged.
HATZ
NOTICE
See also instructions in the documentation for the complete machine.
Operator's Manual 45
Page 45
2
I
0
2
1
Operation and use 4H50TIC
Overview — HATZ instrument boxes
Pos. Designation
1 Starting key
2 Protective cap
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.
2 Remove the starting key.
3 Seal the ignition lock with the protective cap (2).
46 Operator's Manual
HATZ
Page 46
4H50TIC Operation and use
7.6 Checking the oil level and adding oil if necessary
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Wear safety gloves.
Safety notes
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.
HATZ
Operator's Manual 47
Page 47
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
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.
48 Operator's Manual
HATZ
Page 48
i
4H50TIC 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.
7.7 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.
Safety notes
NOTICE
If possible, never run the fuel tank empty, otherwise air can enter the fuel system and the engine switches to the emergency
program. There is also the risk that damage is caused in the fuel
high-pressure section.
If the fuel tank is nevertheless run empty, the procedure described under "7.4 Starting the engine for the first time/after a filter
change, page 42" must be adhered to.
DANGER
Fire hazard from fuel.
Leaked or spilled fuel can ignite on hot engine parts and cause
serious burn injuries.
▪ Only refuel when the engine is switched off.
▪ Never refuel in the vicinity of open flames or sparks that can
cause ignition.
▪ Do not smoke.
▪ Do not spill fuel.
CAUTION
Danger of environmental damage from spilled fuel.
Do not overfill the fuel tank and do not spill fuel.
▪ Collect emerging fuel and dispose of it in an environmentally
compatible manner.
HATZ
Operator's Manual 49
Page 49
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.
▪ 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).
50 Operator's Manual
HATZ
Page 50
4H50TIC Maintenance
8 Maintenance
8.1 General maintenance instructions
HATZ
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 availa-
ble. 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 tasks may only be performed by trained personnel.
▪ Accident prevention measures must be in accordance with the local acci-
dent prevention regulations.
▪ Perform setting and maintenance work at the specified intervals.
▪ Replace faulty machine parts as soon as possible.
▪ Always use personal protective equipment.
▪ Only use fully functional tools.
▪ Problems may occur if unsuitable spare parts are installed. We cannot ac-
cept responsibility for damage and secondary damage that result from
this. We therefore recommend the use of Hatz original spare parts.
▪ Closely adhere to the maintenance conditions prescribed in this Operator's
Manual.
▪ Only make changes on the machine in agreement with the manufacturer.
▪ Only perform maintenance when the engine is switched off.
▪ Adhere to legal regulations when handling and disposing of used oil, fil-
ters, coolants, and cleaning agents.
▪ Protect the starting key against unauthorized access.
▪ Disconnect the negative battery terminal before carrying out maintenance
work.
▪ After completing maintenance work, check that all tools, bolts, aids and
other objects are removed from the machine and that all safety equipment
has been replaced.
Operator's Manual 51
Page 51
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.
▪ After the necessary maintenance and repair work is completed, perform a
function test (test run).
▪ For maintenance work that is not listed and described in the maintenance
documentation, please contact your nearest HATZ service station.
8.2 Maintenance work
Safety note
Danger of injury if maintenance instructions are not followed.
▪ Only perform maintenance when the engine is switched off.
▪ Protect the starting key against unauthorized access.
▪ Disconnect the negative terminal of the battery.
▪ After the maintenance work is completed, ensure that all
CAUTION
tools have been removed from the machine.
8.2.1 Maintenance plan
Symbol Maintenance in-
terval
Every 8-15 operating hours or every day before
starting
52 Operator's Manual
Maintenance activity/Check Chapter
Check the oil level. 7.6 Checking the
Check the intake area of the
combustion air.
oil level and add-
ing oil if necessa-
ry, page 47
8.2.2 Checking
the intake area of
the combustion
air, page 54
HATZ
Page 52
500h
4H50TIC Maintenance
Symbol Maintenance in-
Maintenance activity/Check Chapter
terval
Check the radiator fins for dirt
accumulation.
Checking the cooling system 8.2.4 Checking
Every 500 operating hours or every
Change the engine oil and oil
1)
filter
2 years
Change the fuel prefilter
Change the fuel fine filter
Check the poly v belt
Change the oil separator of the
crankcase ventilation
1)
1)
Check the screw connections1)8.2.10 Checking
Clean the radiator fins
Every 500 operat-
Change the air filter cartridges 8.2.14 Servicing
1)
ing hours or when
indicated, at least
every 2 years
When indicated Drain the water separator
8.2.3 Checking
the radiator fins
for dirt accumula-
tion, page 55
the cooling sys-
tem, page 57
8.2.5 Changing
the engine oil and
oil filter,
page 59
1)
8.2.12 Changing
the fuel prefilter,
page 74
1)
8.2.13 Changing
the fuel fine filter,
page 77
8.2.7 Tensioning
the poly v belt,
page 67
8.2.9 Changing
the oil separator
of the crankcase
ventilation,
page 71
the screw con-
nections,
page 72
8.2.6 Cleaning
the radiator fins,
page 64
the air filter (optional), page 80
1)
8.2.11 Draining
the water separa-
tor, page 73
HATZ
Operator's Manual 53
Page 53
i
Maintenance 4H50TIC
Symbol Maintenance in-
terval
If necessary, ev-
ery 3000 operating hours at the
latest
Every 4000 oper-
ating hours
1)
Service according to service interval or after 2 years depending on which
criteria is first.
In new and generally overhauled engines, after 50 operating hours:
▪ Change the engine oil and oil filter. See the chapter 8.2.5 Changing the
engine oil and oil filter, page 59.
▪ Check the screw connections (do not retighten the screws for attaching
the cylinder head). See the chapter 8.2.10 Checking the screw connec-
tions, page 72.
Maintenance activity/Check Chapter
Replacing the poly v belts 8.2.8 Replacing
Clean the entire EGR section
(EGR precooler, EGR valve,
EGR main cooler as well as
EGR mixing nozzle)
(To be carried out by a trained
specialist)
8.2.2 Checking the intake area of the combustion air
Safety notes
CAUTION
the poly v belts,
page 69
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
54 Operator's Manual
NOTICE
In case of heavy contamination, shorten the maintenance intervals accordingly (see the chapter 8.2.1 Maintenance plan,
page 52).
HATZ
Page 54
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
HATZ
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
Operator's Manual 55
Page 55
i
Maintenance 4H50TIC
Overview
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.
NOTICE
In case of heavy contamination, shorten the maintenance intervals accordingly (see the chapter 8.2.1 Maintenance plan,
page 52).
1 Radiator fins
56 Operator's Manual
HATZ
Page 56
4H50TIC Maintenance
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
Procedure
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. After topping up the cooling system never
move parts of your body or face close to the sealing cap.
▪ Never top up coolant above the MAX - mark on the expan-
sion tank.
▪ Never stop escaping coolant with your bare hands.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
HATZ
CAUTION
Danger of burns.
There is a danger of burns when working on a hot cooling system. The cooling system is pressurized.
▪ Let the engine cool.
▪ Wear safety gloves.
Operator's Manual 57
Page 57
MAX
MIN
MAX
MIN
12
43
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 hori-
zontal and be switched off.
Overview
1 Expansion tank for coolant
2 Sealing cap
3 MAX - Maximum coolant level
4 MIN - Minimum coolant level
Step Activity
1 The coolant must be between the MIN and MAX marks on a
switched-off and cooled-down engine. For a warm engine, the
level can also be slightly above the MAX mark.
Procedure for topping up coolant
Procedure for checking the coolant level
Step Activity
1 Open the sealing cap (2).
2 Top up prepared coolant to the MAX mark on the expansion
tank. Preparation of the coolant, see the chapter 4.4 Coolant,
page 23.
3 Tighten the sealing cap (2) by hand all the way.
58 Operator's Manual
HATZ
Page 58
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).
Overview
1 Hose clip
Procedure
Step Activity
1 Check the cooling system for leaks and rectify the cause imme-
diately - in case of doubt consult HATZ Service for advice.
2 When hose connections are loose, retighten the hose clips (1).
8.2.5 Changing the engine oil and oil filter
HATZ
Safety notes
CAUTION
Danger of burns.
When working on the engine there is a danger of burns from hot
oil.
▪ Wear personal protective equipment (gloves).
Operator's Manual 59
Page 59
i
Maintenance 4H50TIC
Overview of draining engine oil
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 envi-
ronmental 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.
▪ When checking the oil level, the engine must be horizontal
and have been switched off for a few minutes.
NOTICE
▪ The engine must be level.
▪ The engine must be switched off.
▪ Only drain engine oil while it is warm.
1 Oil drain screw (side)
2 Oil drain screw (front)
3 Gasket
60 Operator's Manual
HATZ
Page 60
4H50TIC Maintenance
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.
Procedure
Overview of changing the oil filter (horizontal installation)
1 Oil filter
2 Sealing surface
3 Gasket
HATZ
Procedure
Step Activity
1 Loosen the oil filter (1) with a strap wrench or similar and un-
screw it.
2 Dispose of the old filter in accordance with local environmental
regulations.
3 Thoroughly clean the sealing surface (2).
4 Lightly oil the sealing lip (3) of the new oil filter.
5 Screw in the oil filter and tighten it by hand.
Operator's Manual 61
Page 61
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
Step Activity
1 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.
2 Fully unscrew the oil filter after a waiting period of approx. 30
seconds.
62 Operator's Manual
HATZ
Page 62
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 ele-
ment (3). The guard ring prevents dirt from accumulating between the oil filter and shaped element.
Overview of filling the engine oil
HATZ
1 Dipstick
2 Oil filler plug, top
3 Oil refilling container
4 Oil filler plug, bottom
Operator's Manual 63
Page 63
Maintenance 4H50TIC
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.
Concluding inspection work
Procedure
Step Activity
1 Check the oil level after a short test run and correct if necessary.
2 Check the oil filter for tightness and retighten by hand if neces-
sary.
8.2.6 Cleaning the radiator fins
Safety notes
DANGER
Danger of explosion from flammable cleaning agents.
Cleaning with benzene is an explosion hazard. It is highly flammable, can become electrostatically charged and can generate
an explosive gas-air mixture.
▪ Use halogen-free, cold cleaners with a high flashpoint for
cleaning.
64 Operator's Manual
HATZ
Page 64
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.
▪ Comply with the instructions for preventing fire on the safety
data sheet for the cold cleaner.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
CAUTION
HATZ
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 damage to the machine from incorrect engine
cleaning.
▪ Let the engine fully cool down before cleaning.
▪ Do not spray components of the electrical equipment with a
water jet or high pressure jet during cleaning.
▪ Do not use gasoline or acid-based cleaning agents.
Operator's Manual 65
Page 65
i
1
2
3
Maintenance 4H50TIC
Overview
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
In case of heavy contamination, shorten the maintenance intervals accordingly (see the chapter 8.2.1 Maintenance plan,
page 52).
1 Radiator fins
2 Direction of flow of the cooling air with suction fan
3 Direction of flow of the cooling air with forced-draught fan
66 Operator's Manual
Procedure
Step Activity
Cleaning in case of dry dirt contamination
1 Clean the radiator fins either with compressed air or flush with a
water jet - depending on the amount of accumulated dirt. Work
first against the direction of flow of the cooling air and then in the
direction of flow.
Cleaning of wet or oily dirt contamination
HATZ
Page 66
i
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
New belt 480 N (+ 50 N) 80 Nm (+ 10 Nm) 210 Hz (+ 10 Hz)
Belt after service
Minimum tension
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
NOTICE
▪ Regularly check poly v belts for wear. Replace the poly v
belt immediately when the ribbed profile (inside of the belt)
is worn or broken off.
▪ The cause of running noises for the poly v belt is mostly that
the pretension on the belt is too low.
▪ A too low belt pretension causes early wear of the poly v
belt. Regularly check the belt tension, in case of doubt retension the poly v belt.
▪ The vibration frequency is decisive for adjustment of the belt
tension. The torque values are only a guide value.
Pretension
force
(belt)
250 N (+ 30 N) 70 Nm (+ 10 Nm) 150 Hz (+ 10 Hz)
170 N 125 Hz
Torque
(belt tensioner)
Frequency
(frequency meter)
HATZ
Operator's Manual 67
Page 67
1
2 3
5
4
6
7
Maintenance 4H50TIC
Overview
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
Step Activity
1 Check the poly v belt for wear. Do not retension a worn poly v
belt, but immediately replace it.
68 Operator's Manual
HATZ
Page 68
i
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 clamp-
ing 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.
6 Tighten the torque wrench (6) until the required torque is
reached.
7 Hold the torque wrench and tighten the alternator mounting bolt
at this position.
8 Checking the belt tension with a frequency meter:
Vibrate the end of the belt between the alternator and fan by
lightly hitting it with the hand.
9 Measure the frequency with a commercially available optical or
acoustic frequency meter by following the meter manufacturer's
instructions.
10 If necessary, retension the belt by using a belt tensioner as de-
scribed above.
8.2.8 Replacing the poly v belts
Safety note
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
HATZ
NOTICE
▪ The poly v belt must be replaced after 3000 operating hours
CAUTION
at the latest. If wear is detected, the poly v belt must be immediately replaced.
Operator's Manual 69
Page 69
1
4
5
6
2
3
Maintenance 4H50TIC
Overview
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
Step Activity
1 Disassemble the left half of the protective guard (3) by unscrew-
ing the screws (1) and (2) (at the top and bottom).
2 Loosen the alternator mounting bolt (4) one or two revolutions.
3 Manually press the alternator towards the water pump, slide the
loose poly v belt from the belt wheels.
4 Carefully lift the poly v belt over a fan blade. Turn the fan further
in the counterclockwise direction and lift the belt over the remaining fan blades until it is completely free.
5 Feed a new poly v belt over the fan blade in the same way from
the radiator side.
6 Lay the poly v belt over the belt wheels and tension (see 8.2.7
Tensioning the poly v belt, page 68).
7 Reassemble the protective guard.
70 Operator's Manual
HATZ
Page 70
4
4H50TIC Maintenance
8.2.9 Changing the oil separator of the crankcase ventilation
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool before maintenance.
Safety note
Overview
1 Mounting bolts (captive)
2 Breather cap
3 Oil separator cartridge
4 Vent hose
HATZ
Procedure
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).
3 Remove the used oil separator cartridge dispose of it according
to local environmental regulations.
4 Wipe out the breather housing with a clean cleaning cloth. Make
sure that dirt is not brought into the breather housing.
5 Insert a new oil separator cartridge.
6 Put on the breather cap and tighten the four mounting bolts
(max. 4 Nm). If necessary, reattach the vent hose.
Operator's Manual 71
Page 71
i
1
2
3
Maintenance 4H50TIC
8.2.10 Checking the screw connections
NOTICE
▪ 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.
Safety note
Overview
1 Engine base mounting bolts
2 Vibration damper mounting bolt
3 Chassis frame mounting bolts
Procedure
Step Activity
1 Check the mounting bolts of the engine mountings (4x) and
tighten if needed.
2 Check the condition of all remaining screw connections and
ensure that they are tight (for exceptions, see note).
3 Tighten any lose screw connections.
72 Operator's Manual
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Page 72
1
2
3
4
5
4H50TIC Maintenance
8.2.11 Draining the water separator
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. A corresponding fault message is displayed on the instrument box or
CAN display.
Safety note
Overview
HATZ
1 Bleed screw
2 Drain plug
3 Water level sensor connector
4 Drain socket for extension hose
5 Hose clip (for a fuel tank positioned low)
Procedure
Step Activity
1 Place a suitable container under the drain socket (4) of the drain
plug (2).
NOTE: In inaccessible locations, an extension hose can be connected to the drain socket on the drain plug.
Operator's Manual 73
Page 73
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. This can be seen by a
clear separator.
5 If necessary, release the fuel feed line, dispose of the water-fuel
mixture in an environmentally compatible manner.
8.2.12 Changing the fuel prefilter
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.
Safety notes
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
74 Operator's Manual
HATZ
Page 74
1
4
2
3
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.
▪ Only install fuel filters dry and do not prefill in order to avoid
contamination.
HATZ
Overview
1 Hose clip (fuel feed line)
2 Fuel prefilter
3 Drain plug with integrated water level sensor
Operator's Manual 75
Page 75
Maintenance 4H50TIC
4 Water level sensor cable
Step Activity
1 Block the fuel feed line (1) between the fuel tank and fuel prefil-
ter.
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 inte-
grated water level sensor.
6 Dispose of the used fuel prefilter according to local environmen-
tal regulations.
7 Clean the drain plug with integrated water level sensor and light-
ly oil the sealing surfaces. Screw in the drain plug into the new
fuel prefilter.
8 Lightly oil the gasket of the new fuel prefilter, fit the filter and
tighten it by hand.
9 Release the fuel feed line and connect the cable of the water
level sensor.
10 Start the engine and perform a test run.
NOTE: When starting the engine, adhere to the procedure under
"7.4 Starting the engine for the first time/after a filter change,
page 42".
11 After the test run, check the fuel prefilter and drain plug for
leaks.
Procedure
76 Operator's Manual
HATZ
Page 76
4H50TIC Maintenance
8.2.13 Changing the fuel fine filter
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.
Safety notes
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.
▪ Wear safety goggles.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot engine.
▪ Let the engine cool.
▪ Wear safety gloves.
HATZ
Operator's Manual 77
Page 77
1
2
3
4
5
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.
▪ Only install fuel filters dry and do not prefill in order to avoid
contamination.
Overview
78 Operator's Manual
HATZ
Page 78
4H50TIC Maintenance
1 Bleed screw (not open!)
2 Fuel feed line
3 Fuel fine filter
4 Hose clip
5 Strap wrench
HATZ
Procedure
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 environ-
mental 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.
6 Start the engine and perform a test run.
NOTE: When starting the engine, adhere to the procedure under
"7.4 Starting the engine for the first time/after a filter change,
page 42".
7 After the test run, check the fuel fine filter for leaks.
Operator's Manual 79
Page 79
i
1 5 62 3
42
Maintenance 4H50TIC
8.2.14 Servicing the air filter (optional)
Safety notes
Overview
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
▪ 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.
▪ The filter cartridge may not be washed out or beaten out.
▪ The filter cartridge may be blown out only in exceptional
cases. The pressure must not exceed 5 bar.
80 Operator's Manual
HATZ
Page 80
9
87 9
4H50TIC Maintenance
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
HATZ
Replacing the primary/secondary filters
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).
Replace or clean the primary filter according to the service interval indicator. The primary filter must be replaced every two
years at the latest however, cleaning is no longer possible after
this time.
3 Remove dirt adhering to the inside of the air filter housing (1), air
filter cover (3), and dust discharge valve (4).
4 Pull out and check the secondary filter (5), replace if required.
The secondary filter can not be cleaned. The secondary filter
must be replaced after every fifth replacement of the primary filter, though no later than every two years.
5 Carefully insert new filter elements.
Operator's Manual 81
Page 81
Maintenance 4H50TIC
Step Activity
6 Place the air filter cover on the air filter housing and lock all re-
taining 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.
2 Check the sealing surfaces (9) of the filter cartridge for damage.
3 Check the filter cartridge for tears or other damage in the filter
paper by holding it against the light at a slant or shining light
from a lamp (8) through it. In case of doubt, always replace the
primary filter.
NOTE: The primary filter may only be cleaned once, then it must
be replaced.
8.2.15 Changing coolant
Safety notes
Danger of scalding and risk of environmental damage due
to hot coolant.
▪ Excessive coolant is blown off from the sealing cap on the
▪ Never top up coolant above the MAX - mark on the expan-
▪ Never stop escaping coolant with your bare hands.
CAUTION
expansion tank. After topping up the cooling system never
move parts of your body or face close to the sealing cap.
sion tank.
CAUTION
Danger of burns.
There is a danger of burns when working on a hot cooling system. The cooling system is pressurized.
▪ Let the engine cool.
▪ Wear safety gloves.
82 Operator's Manual
HATZ
Page 82
MAX
MIN
MAX
MIN
12
43
7 8
9
6
5
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 com-
patible manner.
Overview
HATZ
Operator's Manual 83
Page 83
10
Maintenance 4H50TIC
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
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).
2 Open the sealing cap (2) of the expansion tank (1).
3 Unscrew the drain plug (5) and drain the coolant into the con-
tainer.
4 Screw in the drain plug (5) with a new gasket (6) and tighten.
5 Place the collecting contain under the oil cooler (7).
6 Release the hose clamp (8) on the bottom coolant hose (9) and
pull off the hose.
Procedure
7 Drain coolant out of the oil cooler (10) and then reconnect the
bottom coolant hose.
84 Operator's Manual
HATZ
Page 84
4H50TIC Maintenance
Step Activity
8 Filling the cooling system (see the chapter 6.5 Filling the cooling
system, page 35).
HATZ
Operator's Manual 85
Page 85
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 Refuel-
ing, page 49
Systematically
check the entire
fuel supply.
If this does not
yield results:
▪ Open the shutoff
valve.
▪ Check the feed
line to the en-
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
gine.
▪ Check the fuel
prefilter.
▪ Check the fuel
fine filter.
▪ Check the func-
tion of the feed
pump.
Insufficient
compression.
Cylinder and/or piston ring wear.
Injector not fully
functional.
Hydraulic load too
high (especially for
multiple hydraulic
Contact Hatz service.
Contact Hatz service.
Contact Hatz service.
Reduce the hydraulic load – if
possible.
pumps).
For low temperatures (engine does
Pre-glow system
defective.
Contact Hatz service.
not start)
86 Operator's Manual
HATZ
Page 86
4H50TIC Faults
Type of fault Possible causes Remedy Chapter
Fuel gelled due to
insufficient cold resistance.
Check whether the
fuel that emerges
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-resist-
4.5 Fuel,
page 26
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
ance fuel mixture.
Oil is too viscous
causing a too low
starter speed.
Change the engine
oil and add oil of
the right viscosity
class.
8.2.5
Changing
the engine
oil and oil filter, page 59
4.3 Engine
oil, page 22
Insufficiently charged battery.
Machine is not uncoupled.
Check the battery
and contact the
service center if
necessary.
If possible, separate the engine
3.2.4 Electrical equipment,
page 18
from the machine
by uncoupling it.
HATZ
Operator's Manual 87
Page 87
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:
▪ Battery and/or
other cable con-
Check the electrical equipment and
their components.
Contact Hatz service.
3.2.4 Electrical equipment,
page 18
nections are incorrectly connected.
▪ Cable connec-
tions are loose
and/or oxidized.
▪ Ground connec-
tion between the
chassis and engine is corroded.
▪ Battery is faulty
and/or not loaded.
▪ Faulty starter.
▪ Faulty relay,
monitoring elements, etc.
The engine starts,
but does not continue running after
the starter is
switched off.
Machine is not uncoupled.
Fuel prefilter is
clogged.
If possible, separate the engine
from the machine
by uncoupling it.
Change the fuel
prefilter.
8.2.12
Changing
the fuel prefilter,
page 74
Fuel fine filter is
clogged.
Change the fuel
fine filter.
8.2.13
Changing
the fuel fine
filter,
page 77
Fuel supply is interrupted.
Systematically
check the entire
fuel supply.
88 Operator's Manual
HATZ
Page 88
4H50TIC Faults
Type of fault Possible causes Remedy Chapter
Stop signal from
monitoring elements that are associated with the
automatic switchoff (optional):
▪ No oil pressure.
▪ Dirty air filter
unit.
▪ Fuel pressure
too low.
▪ Coolant level too
low.
▪ Excess coolant
temperature.
▪ Excess charge
air temperature.
▪ Faulty three
phase alternator.
▪ Check the oil lev-
el.
▪ Check the de-
gree of dirt contamination of the
air filter, and
clean or renew it
if necessary.
▪ Check the fuel
flow, if necessary
change the fuel
prefilter and fine
filter.
▪ Top up coolant.
▪ Check radiator
fins and clean if
needed.
▪ Contact Hatz
service.
7.6 Checking the oil
level and
adding oil if
necessary,
page 47
8.2.14 Servicing the air
filter (optional), page 80
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
8.2.4
Checking
the cooling
system,
page 57
8.2.6 Cleaning the radiator fins,
page 64
Engine switches off
spontaneously during operation.
The tank ran out of
fuel during operation
Fuel prefilter or fine
filter is clogged
Fill with fuel. 7.7 Refuel-
ing, page 49
Change the fuel filter.
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
HATZ
Operator's Manual 89
Page 89
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 serv-
ice.
Engine switches off
by the automatic
electrical switch-off.
Stop signal of monitoring elements
for:
▪ Oil pressure too
low.
▪ Dirty air filter
unit.
▪ Fuel pressure
too low.
▪ Coolant level too
low.
▪ Excess coolant
temperature.
▪ Excess charge
air temperature.
▪ Faulty three
phase alternator.
▪ Check the oil lev-
el.
▪ Check the de-
gree of dirt contamination of the
air filter, and
clean or renew it
if necessary.
▪ Check the fuel
flow, if necessary
change the fuel
prefilter and fine
filter.
▪ Top up coolant.
▪ Check radiator
fins and clean if
needed.
▪ Contact Hatz
service.
7.6 Checking the oil
level and
adding oil if
necessary,
page 47
8.2.14 Servicing the air
filter (optional), page 80
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
8.2.4
Checking
the cooling
system,
page 57
8.2.6 Cleaning the radiator fins,
page 64
90 Operator's Manual
HATZ
Page 90
4H50TIC Faults
Type of fault Possible causes Remedy Chapter
Irregularities in the
electrical equipment, such as:
▪ Loose contacts
on cable connec-
Check the electrical equipment and
its components,
contact Hatz service if necessary.
3.2.4 Electrical equipment,
page 18
tions.
▪ Faulty three
phase alternator.
▪ Faulty relay.
The engine loses
power and speed.
Engine runs due to
an error in the
emergency program.
Switch off the engine, wait for a min.
of 2 minutes, then
restart the engine.
(This deletes minor
errors).
7.5 Switching off the
engine,
page 45
7.3 Starting
the engine,
page 39
The engine loses
power and speed,
and black smoke
emerges from the
exhaust.
The fuel supply is
impaired
▪ The tank ran out
of fuel during operation.
▪ Fuel prefilter or
fine filter is clogged.
▪ Inadequate tank
venting.
▪ Line connections
are not leak tight.
Dirty air filter unit. Check the degree
Turbocharger faulty
or leaking hoses.
Add fuel.
Change the filter.
Ensure that the
tank is sufficiently
vented.
Check the line
screw connections
for leak tightness.
of dirt contamination of the air filter,
and clean or renew
it if necessary.
Check hoses or
contact Hatz serv-
7.7 Refueling, page 49
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
8.2.14 Servicing the air
filter (optional), page 80
ice.
Injector not fully
functional.
Contact Hatz service.
HATZ
Operator's Manual 91
Page 91
Faults 4H50TIC
Type of fault Possible causes Remedy Chapter
Engine becomes
very hot.
Indicator light for
excess coolant
temperature lights
up.
Too much engine
oil in the engine.
Inadequate cooling:
▪ Contamination in
the entire area of
the cooling air
guides.
▪ Radiator fins
dirty, or radiator
blocked.
Drain the engine oil
to the max mark on
the dipstick.
▪ Clean the cooling
air area.
▪ Clean the radia-
tor fins, ensure
air flow through
radiator is not
hindered.
▪ Contact Hatz
service.
7.6 Checking the oil
level and
adding oil if
necessary,
page 47
8.2.6 Cleaning the radiator fins,
page 64
8.2.4
Checking
the cooling
system,
page 57
▪ Thermostat or
water pump faulty.
Combined indicator
on instrument box
flashes.
Various errors in
different assemblies.
Use the flash code
table to identify and
rectify errors.
Flash signal
Possible causes Remedy Chapter
Short – Long
Flash code table
1 – 1
Area affected:
Monitoring of indicating and control
elements
▪ Indicator(s) or
cabling faulty.
▪ Insufficient con-
trol unit power
supply.
▪ Other errors not
specified in more
detail.
1 – 2
Area affected:
Speed sensor sys-
▪ Crankshaft or
camshaft sensor
cabling faulty.
tem
92 Operator's Manual
▪ Check the func-
tion and cabling
of the indicators.
▪ Check the power
supply of the
control unit.
▪ Check the ca-
bling.
HATZ
Page 92
4H50TIC Faults
Flash signal
Short – Long
1 – 3
Area affected:
Air supply
1 – 4
Area affected:
Exhaust gas recirculation
2 – 1
Area affected:
Fuel low pressure
system
2 - 2
Area affected:
Fuel high pressure
system
Possible causes Remedy Chapter
▪ Air filter is dirty.
▪ Charge air after
charge air cooler
too high.
▪ Charge air sen-
sor/intake low
pressure sensor
cabling faulty.
▪ EGR sensor ca-
bling faulty.
▪ EGR radiator/
valve clogged by
▪ Service the air fil-
ter
▪ Clean the radia-
tor fins.
▪ Check the ca-
bling.
▪ Check the ca-
bling.
▪ Clean the EGR
radiator/valve.
8.2.14 Servicing the air
filter (optional), page 80
8.2.6 Cleaning the radiator fins,
page 64
deposits.
▪ Water in fuel.
▪ Fuel pressure
too low.
▪ Fuel temperature
too high.
▪ Fuel pump or
sensor cabling
faulty.
▪ Drain water from
the fuel prefilter.
▪ Check the fuel
tank level, refuel
if required.
▪ Replace both
fuel filters.
▪ Ensure the fuel is
sufficiently
cooled.
▪ Check the ca-
bling.
8.2.11
Draining the
water separator,
page 73
7.7 Refueling, page 49
8.2.12
Changing
the fuel prefilter,
page 74
8.2.13
Changing
the fuel fine
filter,
page 77
▪ Sensor system
(injectors, rail
▪ Check the ca-
bling.
pressure sensor,
pressure control
valve, high pressure pump) cabling faulty.
HATZ
Operator's Manual 93
Page 93
Faults 4H50TIC
Flash signal
Short – Long
2 – 3
Area affected:
Engine oil temperature/engine oil
pressure
3 – 1
Area affected:
Liquid cooling
3 – 2
Area affected:
Pre-glow system
Possible causes Remedy Chapter
▪ Engine oil pres-
sure too high/too
low.
▪ Engine oil tem-
perature too
high.
▪ Sensor cabling
faulty.
▪ Check the oil lev-
el, top up engine
oil if required.
▪ Use engine oil
with a suitable
viscosity.
▪ Check the water
hoses for the oil
7.6 Checking the oil
level and
adding oil if
necessary,
page 47
4.3 Engine
oil, page 22
cooler (hose
kinked).
▪ Clean the oil
cooler if required.
▪ Check the ca-
bling.
▪ Coolant level too
low.
▪ Coolant tempera-
ture too high.
▪ Coolant tempera-
ture sensor cabling faulty.
▪ Temperature
sensor faulty.
▪ Glow plugs ca-
bling faulty.
▪ One or multiple
glow plugs faulty.
▪ Glow control unit
▪ Top up coolant.
▪ Clean the radia-
tor fins.
▪ Check the ca-
bling.
▪ Replace the tem-
perature sensor.
▪ Check the ca-
bling.
▪ Check the func-
tion of the glow
plugs.
8.2.4
Checking
the cooling
system,
page 57
8.2.6 Cleaning the radiator fins,
page 64
(GCU) faulty.
94 Operator's Manual
HATZ
Page 94
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).
Storing the machine for a lengthy period
Take the following measures if you intend to take the machine out of service
for a lengthy period:
Step Activity
1 Drain the fuel tank until it is nearly empty and fill with RME-free
fuel. Run the engine for a few minutes so that only RME-free
fuel is still in the fuel system.
2 After the machine has cooled down, cover it to protect it against
dust and store it in a dry and clean place.
The machine can normally be stored for up to 1 year.
The protection lasts up to approx. 6 months at very high humidity and with
sea air.
If the storage time is longer, please contact the nearest Hatz service.
10.2 Disposing of the machine
Disposal information
Dispose of the machine (including machine parts, engine oil, coolant, and
fuel) according to the local disposal regulations and the environmental laws
in the country of use.
Because of the danger of possible environmental damage, only permit an
approved specialist company to dispose of the machine.
HATZ
Operator's Manual 95
Page 95
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).
▪ Do not dispose of the battery with the household trash.
▪ Dispose of the battery at a collection point for possible recy-
cling.
96 Operator's Manual
HATZ
Page 96
4H50TIC Installation declaration
11 Installation declaration
HATZ
Operator's Manual 97
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