Hatz Diesel 4H50TIC, Workshop Manual

Page 1: ...Workshop Manual 4H50 TIC 439 002 00 07 2015e Printed in Germany...

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Page 3: ...etails Lubricating oil circuit Cooling circuit Sealants and adhesives Special tools and workshop equipment 2 Additional equipment Z 01 Main fuel filter Z 02 Suction hose Z 03 Oxidation catalytic conve...

Page 4: ...7 Rocker arm M 08 Cylinder head cover Z 05 Glow plugs M 07 Thermostat temp sensor M 28 Exhaust manifold M 28 Turbocharger M 30 Lifting device M 37 Exhaust gas return M 14 Injection system M 31 Crankca...

Page 5: ...t is a prerequisite that normal hand tools are at hand With respect to maintenance work tools troubleshooting etc we refer to the operator s manual Only use genuine Hatz original spare parts for repai...

Page 6: ...1 3 4H50 07 2015...

Page 7: ...1 3 4H50 07 2015 1 General...

Page 8: ...Oil filter 8 Fine fuel filter 9 Side oil drain screw 10 Starter low installation position 11 Electric fuel pump 12 Fuel pre filter 13 Drain screw on the fuel pre filter 14 Engine type plate 15 Dipsti...

Page 9: ...n 2 Oil filler screw top 3 Exhaust gas turbocharger 4 Oxidation catalytic converter 5 Exhaust gas discharge 6 Starter high installation position 7 Oil drain screw front 8 Poly v belt 9 Radiator option...

Page 10: ...x 1 of fuel consumption with respect to full load Engine oil pressure 2 5 bar to 4 5 bar Coolant quantity with HATZ standard radiator and expansion tank Approx ltr 12 5 Direction of rotation when look...

Page 11: ...CI engines Use in Constant Speed Applications only EU Type e197 68PA 2011 88 0699 01 IIIB 120R 001022 00 24R 033147 www hatz diesel com E1 187_44_C_3B The engine type plate is affixed to the crankcas...

Page 12: ...1 Oil intake pipe 2 Oil pressure relief valve 3 Oil pump 4 Oil cooler 5 Oil filter 6 Check valve 7 Camshaft 8 Oil pressure sensor 9 Roller tappet with HVA element 10 Push rod 11 Rocker arm bearing blo...

Page 13: ...pump intake Coolant pump Water pump pressure side EGR manifold Bypass Radiator Coolant expansion tank EGR main radiator Oil radiator EGR pre radiator Cabin heating Crank case input manifold Cylinder...

Page 14: ...ing circuit diagram 4H50 within the engine Return coolant radiator Return expansion tank Water pump intake Bypass thermostat Water pump Water pump pressure side Crank case Input manifold Crank case ou...

Page 15: ...circuit Cooling circuit diagram 4H50 radiator and cabin heating Intake from crank case output manifold Air vent radiator Return pipe cabin heating Supply from radiator to water pump intake Input radia...

Page 16: ...ake EGR manifold crankcase manifold EGR Valve EGR manifold EGR pre cooler Return from EGR to coolant manifold EGR main cooler Coolant manifold Intake from EGR manifold to oil radiator Return from oil...

Page 17: ...ives Application of sealant and adhesive material 502 230 01 Loctite Activator 500 ml 700 189 18 Loctite 243 50 ml 502 234 00 Loctite 648 10 ml 502 825 01 Silicon 30 ml 700 218 15 Silicon 300 ml 502 8...

Page 18: ...474 00 700 113 94 702 534 99 702 534 97 702 534 98 Piston ring collet chuck 70 100mm Multi tooth wrench socket M8 Strap wrench Piston ring expander Socket wrench for cyl K E14 1 2 Socket wrench SW 27...

Page 19: ...1 3 4H50 07 2015 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 20: ...ssembly engine Designation 1 2 3 4 5 653 480 00 653 466 00 653 464 00 653 517 00 702 517 89 Counterholder for flywheel Assembly pin for roller tappet Magnet holder for roller tappet guide Turning devi...

Page 21: ...1 3 4H50 07 2015 1 2 3 4 5...

Page 22: ...50 07 2015 Special tools and workshop equipment Component servicing Designation 1 2 3 629 223 01 634 142 00 634 143 00 Valve lifting tool Honing tools 50 175 Replacement stones for honing tools Ident...

Page 23: ...1 3 4H50 07 2015 1 2 3...

Page 24: ...197 00 Part cannot be ordered individually please order group Part cannot be ordered individually please order group Engine mountings F2F Guard tube Adapter for guard device Base frame large Machine...

Page 25: ...1 3 4H50 07 2015 1 2 3 1 2 4 5 6 7 10 8 9 8 9...

Page 26: ...624 851 01 624 861 01 653 290 00 635 303 90 631 147 90 630 705 00 630 706 00 634 287 00 634 286 00 Temperature measurement device Sensor extension cable Assembly table Adapter flange 6 8 hole Driven f...

Page 27: ...1 3 4H50 07 2015 C 1 2 3 4 6 7 8 9 5...

Page 28: ...0 702 503 97 Revolution counter for fuel pressure pipe Part cannot be ordered individually please order group Charging cable with 12V pole clamps Part cannot be ordered individually please order group...

Page 29: ...1 3 4H50 07 2015 7 4 2 3 5 6 11 12 10 9 8 1 2 7 13 13...

Page 30: ...nostic equipment Designation 1 2 3 4 5 653 772 00 702 536 30 Part cannot be ordered individually please order group Part cannot be ordered individually please order group Diagnostic tool Bosch VCI BG...

Page 31: ...1 3 4H50 07 2015 1 2 3 4 1 3 VCI 5...

Page 32: ...1 3 4H50 07 2015 Special tools and workshop equipment Cooling system Designation 1 2 702 530 56 702 530 57 Radiator vacuum filling device Tank for filling device Ident no No...

Page 33: ...1 3 4H50 07 2015 1 2...

Page 34: ...1 3 4H50 07 2015 Special tools and workshop equipment Electrical equipment Designation 1 2 700 318 32 700 348 26 Crimping pliers Garant F28 95 Mounting pliers Deutsch HDT 48 00 Ident no No...

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Page 37: ...2 3 4H50 07 2015 2 Additional equipment...

Page 38: ...2 x cylinder screw M 10x30 46 Nm KRST main fi lter 2 x sealing ring A 16x22 Ring nipple KRST line Hollow screw 10 3 55 5 Nm Absolute cleanliness Protective caps may only be removed from the parts dir...

Page 39: ...2 3 4H50 07 2015 Hexagon nut M 6 2 x cylinder screw M 6x12 9 5 Nm Bracket Cylinder screw M 6x16 9 5 Nm Pressure sensor Sleeve Adapter fittings Z 02 Suction hose...

Page 40: ...ping flange and support 2 x washer 10 5 2 x cylinder screw M 10x30 Secure with Loctite 243 46 Nm Gasket 2 x spacers 2 x washer 10 5 2 x cylinder screw M 10x60 46 Nm Fastening 2 x washer A 8 4 2 x hexa...

Page 41: ...belt 480 50 N Pretensioning after service 250 30 N Minimum pretensioning force 170 N Cylinder screw M 10x130 46 Nm Hexagon nut M 8 Washer B 8 4 Flange sleeve Cylinder screw M 8x35 23Nm Alternator 14V...

Page 42: ...2 3 4H50 07 2015 Z 05 Starter Starter bracket cover 2 x washer 10 4 2 x cylinder screw M 10x35 46 Nm Starter 12V 2 2 kW 2 x washer 10 4 2 x cylinder screw M 10x45 46 Nm...

Page 43: ...M 10x55 46 Nm 2 x cylinder screw M 10x35 in the crankcase 46 Nm 4 x cylinder screw M 10x40 in connection housing 46 Nm 3 x engine base Cover plate with oil filler and engine base O ring 7x2 FPM Apply...

Page 44: ...2 3 4H50 07 2015 Threaded pin M 8x10 Oil cooler_KTR Double nipple Secure with Loctite 648 40 Nm Throw away filter 10 Nm Z 07 Oil cooler...

Page 45: ...Shaped hose piece fastened with 2 x hose clamp DIN 3017 A 12 22x9 3 Nm 1 x hose clamp DIN 3017 A 16 27x12 5 Nm 1 x hose clamp DIN 3017 A 20 32x13 5 Nm Pipe clamp RSGU 1 25 15 Washer 6 4 Hexagon bolt...

Page 46: ...2 3 4H50 07 2015 Exhaust fan 3 x spring washer A 6 3 x cylinder screw M 6x35 9 5 Nm Spacer for fan Z 30 Fan...

Page 47: ...3 3 4H50 07 2015 3 Basic engine equipment...

Page 48: ...3 3 4H50 07 2015 M 01 Cylinder crankcase Dipstick complete Oil pressure sensor DS M1 TF 37 5 Nm Check valve Heed installation posi tion...

Page 49: ...spring Sealing ring A 24x29 Screw plug M 24x1 5 100 10 Nm Secure tube connectors with Loctite 648 and press into cylinder block up to the stop Secure check valve Provent with Loctite 243 12 5 2 5 Nm S...

Page 50: ...3 3 4H50 07 2015 Oil spray nozzle Valve screw N8 27 2 Nm Piston cooling complete M 01 Cylinder crankcase...

Page 51: ...in bearing halves into cylinder block main bearing bracket and moisten with engine oil Heed the correct posi tion of the oil holes and the position groove Insert thrust washer with grease Oil pockets...

Page 52: ...gh correct mounting of the main bearing bracket with thrust washers Before tightening the screws on the main bearing bracket put the crankshaft and the main bearing bracket in the specified direction...

Page 53: ...3 3 4H50 07 2015 3 1 5 7 9 4 2 6 8 10 M 02 Crankshaft Tighten main bearing bracket in the specified sequence Tightening torque 1st level 10 Nm 2nd level 45 Nm 3rd level 90 Nm...

Page 54: ...ar ing points with engine oil and insert camshaft into cylinder block M 04 Camshaft Cylinder pin 8 x 50 Threaded pin M10 x 10 Mount with Loctite 243 Tighten threaded pin up to stop max 5 Nm then loose...

Page 55: ...3 4H50 07 2015 M 02 Crankshaft gear wheel Place crankshaft gear wheel on crankshaft heeding the correct positioning of the mark ings Press spring pin into crankshaft gear wheel to specified dimension...

Page 56: ...3 3 4H50 07 2015 Apply sealing agent Loctite 5910 according to the black curve M 01 Connector housing WDRI 55x70x8 Oil slightly and press in until flush with flange surface...

Page 57: ...al tool onto cylinder block 2 23 Nm Screw special tool onto connector housing 3 23 Nm this aligns the flange surface Tighten only the three screws 1 with 10 12 Nm Loosen screws 3 in order to avoid dis...

Page 58: ...amaged by the sprocket Keep soiling to a mini mum Front side is magnetic Avoid contact with iron particles M 17 Flywheel Speed sensor DG6 S for flywheel Cylinder screw M 6x20 8 8 9 5 Nm Sprocket Mount...

Page 59: ...5x10 8 8 5 5 Nm Bulkhead Rotor set M 10 Oil pump Rope seal Grease slightly for mounting 2x spring pin 8x8 Cover for oil pump WDRI 40x62x7 Grease slightly for mounting and press in flush with housing 8...

Page 60: ...4H50 07 2015 Special tool 651 692 00 Remove after tighten ing the pulley Z 30 Pulley Pulley crankshaft 103 PK6 Bevel to the crankshaft Tension washer 16 Cylinder screw M 16x1 5x40 LH Left thread 200...

Page 61: ...0 heed notch for oil spray nozzle Tighten conrod screws 20 Nm 65 M 05 Piston and conrod Connect piston to con rod position grooves of the conrod bearing and notch for the oil spray nozzle on the pisto...

Page 62: ...3 3 4H50 07 2015 Intake manifold complete 2 x cylinder screw M 8x16 8 8 Glued in with Loctite 243 23 Nm M 10 Intake manifold Apply surface sealant Loctite 5910 here...

Page 63: ...ning Cu sealing ring Magnet screw plug AM 22x1 5 50 Nm M 01 Oil sump Apply surface sealant Loctite 5910 here ac cording to the red area 2nd screw connection long hole serves the alignment Combi screw...

Page 64: ...3 3 4H50 07 2015 2 x spring pin 8x8 first mount in crank shaft Cylinder screw M 6x20 9 5 Nm Phase encoder for NW 11x cylinder screw M 6x20 9 5 Nm M 36 Water pump...

Page 65: ...Insert guide pins with special tool 653 464 00 into crankcase Ensure with a slight turning of the roller tap pet that the guide pin is in the groove of the roller tappet Threaded pin M 10x10 Mount wit...

Page 66: ...lve cone MK6 Plate spring Valve spring inlet outlet Valve spring outlet Valve shaft seal Plate for valve spring Valve disk inlet Valve disk outlet Insert and remove valves with special tool 629 223 01...

Page 67: ...74 00 and select cylinder head seal according to table M 07 Cylinder head Choosing the right cylinder head seal engine H50 Gap 0 6 0 7 projecting measurement Gap SM mm projecting measurement of the pi...

Page 68: ...ombi screw M 12x130 Tightening process 1 10 1st stage 20 2 Nm 2ndstage 75 5 3rdstage 75 5 greased with TA White Cylinder screw M 6x80 Tightening process 11 14 9 5 Nm 1 5 7 3 9 2 4 8 6 10 12 11 13 14 M...

Page 69: ...cker arm bearing block with axle Rocker arm outlet com plete Locking ring A 18x1 M 07 Rocker arm Rocker arm inlet com plete Locking ring A 18x1 as needed Adjusting ring 15x21x0 2 Adjusting ring 15x21x...

Page 70: ...the lock nut and turn adjusting screw in until the calotte of the ad justing screw lies against the spherical head of the push rod From this position turn the adjusting screw 1 1 4 turns in and secure...

Page 71: ...3 3 4H50 07 2015 Hexagon bolt M 6x20 F A3B 9 5 Nm Cylinder head cover Paper seal for the cylinder head cover M 08 Cylinder head cover Screw plug for oil filler with RK ring 26x35x3 tighten hand tight...

Page 72: ...3 3 4H50 07 2015 Hexagon nut M 4 max 2 5 Nm Washer 4 3 Pencil glow plug GLP 2 11V apply high temperature paste 10 15 Nm Z 05 Glow plugs...

Page 73: ...5 Housing thermostat Washer 6 4 Hexagon bolt M 6x25 M 07 Thermostat temp sensor Temperature sensor TS cooling water max 25 Nm O ring 58x2 Only fasten with silicone grease OPTISIL FM High temperature s...

Page 74: ...3 3 4H50 07 2015 Gasket installation position the raised side of the bead must point towards the exhaust manifold Hexagon nut VM 8 25 2 Nm Sealing ring Screw plug G 1 4 30 Nm M 28 Exhaust manifold...

Page 75: ...45 Nm M 28 Turbocharger Hollow screw 6 S 10 Nm 2 x sealing ring A 10x13 5 2 x sealing ring A 12x15 5 Hollow screw M 12x1 5 26 Nm Pressure oil line Turbocharger Gasket for the turbo charger position f...

Page 76: ...3 3 4H50 07 2015 Lifting eye 2 x cylinder screw M 8x20 23 Nm M 30 Lifting device...

Page 77: ...nd the housing with bracket must first be pre mounted with out tightening and then tightened in the speci fied sequence Washer 10 5 2 x hexagon bolt M 10x70 A3C 2 x cylinder screw M 8x25 A3C 23 Nm Con...

Page 78: ...3 4H50 07 2015 2 x gasket AGR cooler Heed installation posi tion marking 4 x cylinder screw M 8x25 A3C Bracket 4 x cylinder screw M 8x20 A3C 2 x hexagon nut VM 8 Housing Gasket M 37 Exhaust gas retur...

Page 79: ...gas return Tightening sequence Position 1 2 x hexagon nut VM 8 23 Nm Position 2 2 x cylinder screw M 8x25 23 Nm Position 3 2 x cylinder screw M 8x25 23 Nm Position 4 2 x hexagon bolt M 10x70 46 Nm Pos...

Page 80: ...015 4 x cylinder screw M 5x12 5 5 Nm Bar AGR valve 2 x hexagon bolt M 6x16 9 5 Nm O ring 8x2 Shaped hose piece 16x4 5 2 x hose clamp 12x22x9 Shaped hose piece 22x4 5 2 x hose clamp 20x32x13 M 37 Exhau...

Page 81: ...7 2015 Hose clamp with wave spring Shaped hose piece 45 x 5 Hose clamp with wave spring Cylinder screw M 5x16 5 5 Nm Washer 5 3 Pressure temp sensor DS S3 TF for charge air Sensor holder M 37 Exhaust...

Page 82: ...fastened properly before start up If necessary injector specific data such as the IMA code must be transferred to the control unit These serve the correct activation of the injectors and thus the inte...

Page 83: ...ounting aids The mounting of the return line on the engine is done by hand Mounting Plug return plug on injector return connection until contact of the contact surface is on the injector picture 1 The...

Page 84: ...he position CP4 marking visible through inspection hole in the connection housing The marking on the high pressure pump is now in the position shown This is the basic position for the mounting of the...

Page 85: ...3 3 4H50 07 2015 Fuel line mount on the return connection before installation of the high pressure pump High pressure pump CP4 3 x hexagon bolt with flange M 8x30 23 Nm M 14 Injection system...

Page 86: ...Fuel line Washer 8 1x20x3 Hexagon nut M 8 Lug Fuel pressure tube 10 Nm 60 rail side 15 Nm 60 pump side 2 x cylinder screw M 8x20 23 Nm High pressure rail 2 x hexagon bolt with flange M 8x30 23 Nm M 14...

Page 87: ...4H50 07 2015 Fuel pressure tube Cylinder 3 4 10 Nm 60 Fuel pressure tube Cylinder 1 2 10 Nm 60 Fuel return line CR injector Hexagon nut M 8 23 Nm Bushing for injector Clamping claw M 14 Injection sys...

Page 88: ...2015 Provent 100 with exchangeable oil sepa rator Shaped hose piece 2 x hexagon bolt with flange M 8x30 23 Nm 2 x wire hose clamp ID 23x1 Shaped hose piece 2 x wire hose clamp ID 18x1 M 31 Crankcase...

Page 89: ...4 3 4H50 05 2016 4 Tables...

Page 90: ...4 3 4H50 05 2016...

Page 91: ...tightening torque 8 8 5 8 10 9 12 9 Thread Screw quality M 4 M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 M22 1 7 3 4 6 0 14 29 50 80 120 170 240 320 2 8 5 5 9 5 23 46 80 130 190 270 380 510 3 9 7 8 13 33 65...

Page 92: ...4 3 4H50 05 2016 Screw tightening torque...

Page 93: ...4 3 4H50 05 2016 Screw tightening torque...

Page 94: ...r Indicator light for alternator control Indicator light for oil pressure Indicator light for engine temperature Indicator light for air filter maintenance switch Indicator light for belt break Indica...

Page 95: ...for speed adjustment Temperature switch for engine temperature Oil pressure switch Pressure switch for air filter Fan monitoring switch Temperature switch for pre glowing Remote start switch Remote s...

Page 96: ...eed fine adjustment 12 Oil pressure sensor 13 Reserved for special application 14 Speed adjustment magnet excitation circuit 15 Reserved for special application 16 Lift magnet for decompression 17 Mai...

Page 97: ...CRankshaft Speed Sensor ATS B8 Ansaugluft Temperatur Sensor Air Temperature Sensor WFS B9 Wasser im Kraftstoff Sensor Water in Fuel Sensor CLS S7 K hlmittel Niveau Sensor Coolant Level Sensor AFDPS B1...

Page 98: ...t c h F T L S W 2 F u e l t a n k l e v e l s e n s o r 2 E N G N E n g i n e s p e e d o u t p u t C O N V C l u t c h s w i t c h K 6 8 R H 2 2 S w i t c h e d b a t t e r y U B 2 H i g h s i d e d...

Page 99: ...n s o r W F S W a t e r i n f u e l l e v e l s e n s o r E G R P S E G R P 3 d i f f e r e n t i a l p r e s s u r e s e n s o r S T R T L P S P R L Y 1 S t a r t r e l a y e l e c t r i c f u e l p...

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Page 110: ...Pin No Pin assignment Pin 1 Supply B cc 2 Supply B dd 3 CAN high aa 4 CAN low bb 5 shield 6 not assigned sensor output signal motor connector Customer control unit Connection CAN speed adjustment cust...

Page 111: ...rotary knob Pin No Pin assignment Farbe Pin Signal 1 1 Voltage supply 5 V Rot A 2 Ground Blau C 4 Signal 0 5 V 4 5 V Braun B Signal 2 6 Voltage supply 5 V Orange D 5 Ground Schwarz F 3 Signal 0 25 V 2...

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Page 127: ...ror Water in fuel pressure too low fuel temperature too cabling pump or sensor faulty Remedies Drain water at fuel pre check tank contents or replace clogged fuel ensure cooling of the check cabling 2...

Page 128: ...4 3 4H50 05 2016 Charge current curve 12 V Charge current A Engine speed rpm Ambient temperature 25 C Ambient temperature 80 C...

Page 129: ...4 3 4H50 05 2016 Charge current curve 24 V Charge current A Engine speed rpm Ambient temperature 25 C Ambient temperature 80 C...