Workshop Manual

4 H50 TIC
439 002 00 - 07.2015e Printed in Germany
Contents

Preface

1. General 2. Additional equipment

Engine illustrations Z 01 Main fuel filter
Technical data Z 02 Suction hose
Type plate details Z 03 Oxidation catalytic converter
Lubricating oil circuit Z 05 Alternator
Cooling circuit Z 05 Starter
Sealants and adhesives Z 06 Engine base
Special tools and workshop equipment Z 07 Oil cooler
Z 30 Fan
Contents

3. Basic engine equipment

M 01 Cylinder crankcase
M 02 Crankshaft
M 04 Camshaft
M 02 Crankshaft gear wheel
M 01 Connector housing
M 17 Flywheel
M 10 Oil pump
Z 30 Pulley
M 05 Piston and conrod
M 10 Intake manifold
M 01 Oil sump
M 36 Water pump
M 01 Roller tappet
M 07 Cylinder head
M 07 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 Crankcase ventilation

4. Tables

Screw tightening torque

Identification on wiring diagrams
HATZ cable marking
Bosch designation for cable marking
Cable harness max.
Cable harness min.
Wiring diagrams
CAN speed adjustment
Analog speed adjustment
Analog speed adjustment
Cable routing
Charge current curve
Preface

This Workshop Manual corresponds to the technical status as stated

on each page (month / year). It has been conceived so that only a trained mechanic (instructed
yearly) can perform all repairs trouble-free.

Notes on how to clean parts etc. have been omitted, as it is taken for granted that this is known
and will be accomplished.

All work may only be performed with the specified or absolutely equivalent tools.
It 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 repairs!

Only these parts guarantee problem-free dimensional accuracy and quality.

In addition, the general statutory regulations and those of the responsible professional trade as-
sociations apply.

Potential discrepancies due to special equipment are possible and can neither be accounted for in
the Workshop Manual nor in the Spare Parts list.
In case of any difficulties, please contact the nearest HATZ service office.
1 3 - 4H50 / 07.2015
1. General

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1
Engine description

1 2 3 4

5
5

17

16

15
6
14

13 12 11 10 9 8
Intake side

1 Intake opening for combustion air 10 Starter (low installation position)

2 Rain cap 11 Electric fuel pump
3 Air filter (option) 12 Fuel pre-filter
4 Dust discharge valve 13 Drain screw on the
5 Lifting eyes fuel pre-filter
6 Fan 14 Engine type plate
7 Oil filter 15 Dipstick
8 Fine fuel filter 16 Oil filler screw bottom
9 Side oil drain screw 17 Crankcase ventilation

1 3 - 4H50 / 07.2015
Engine description

1 2 3

9 8 7 6 5 4

Exhaust side

1 Expansion tank for coolant 6 Starter (high installation position)

(option) 7 Oil drain screw front
2 Oil filler screw top 8 Poly v belt
3 Exhaust gas turbocharger 9 Radiator (option)
4 Oxidation catalytic converter
5 Exhaust gas discharge

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1
Technical data

Type 3H50TIC 4H50TIC

Type Liquid-cooled four stroke diesel engine
Combustion system Direct injection,
turbocharger with charge air cooling,
cooled exhaust-gas recirculation
Injection system Bosch common rail
Number of cylinders 3 4
Bore/stroke mm 84/88 84/88
Displacement cm3 1464 1952
Fill quantity of lubricating oil Approx. ltr. 5.25? 1) 7.0 1)
Difference between "max" and "min"
Approx. ltr. ? 1) 1.0 1)
marking
Engine oil consumption Max. 1% of fuel consumption,
(after running-in period) with respect to full load
Engine oil pressure 2.5 bar to 4.5 bar
Coolant quantity with
HATZ standard radiator Approx. ltr. ? 12.5
and expansion tank
Direction of rotation Left
when looking at flywheel
Tappet clearance Automatic tappet clearance compensation
Max. perm. inclination during 30° 2)
continuous operation in every direction:
Weight (incl. radiator and catalytic
approx. kg ? 226
converter) without operating fluids
Battery capacity Max. 12 V – 110 Ah / 450 A according to DIN
24 V – 66 Ah / 300 A according to DIN

1)
These details must be understood as approx. values.
Relevant is in every case the max. marking on the dipstick.
2)
Exceeding these values causes engine damage.

1 3 - 4H50 / 07.2015
Engine type plate

EMISSION CONTROL INFORMATION

MOTORENFABRIK HATZ GMBH
+CO KG ¬ D-94099 RUHSTORF
www.hatz-diesel.com 8
Model: 4H50TIC – 162J
S/N: 1471014000001 Build: 2014/03
Power: 55,0kW @ 2800 RPM Constant
Displ: 1,95L

Eng.Fam: DHZXL1.95V51
Emission Control System: DFI, DOC, EGR, ECM, TC
Power Category: 37-56kW, PM Standard 0.035
ULTRA LOW SULFUR DIESEL FUEL ONLY. DEL ASSY.
This engine complies with emission regulations for U.S. EPA regulations
MY2014 and California regulations for MY2014 for Non-Road CI engines.
Use in Constant-Speed Applications only.
9
EU-Type: e197/68PA*2011/88*0699*01 (IIIB)
120R-001022*00
E1 24R-033147
187_44_C_3B

The engine type plate is affixed to the crankcase and includes the following engine information:

1 Model designation of the engine

2 Engine number (serial number of the engine)
3 Engine output (kW) at rated speed (min-1)
4 Displacement (liters)
5 Information for US emissions certification (EPA/CARB)
6 EU type approval
7 EU country of origin (Germany)
8 Year of construction (year/month)
9 Bar code (engine number)

The following data must always be specified in case of queries and for spare parts orders:

1 Model designation
2 Engine number

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1
Lubricating oil circuit

11 12
10
6 7 8 9

13

14

5 4

3 2 1

1 Oil intake pipe 8 Oil pressure sensor

2 Oil pressure relief valve 9 Roller tappet with HVA element
3 Oil pump 10 Push rod
4 Oil cooler 11 Rocker arm bearing block with injection
5 Oil filter nozzles
6 Check valve 12 Turbocharger
7 Camshaft 13 Piston cooling
14 Crankshaft

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 Cooling circuit diagram 4H50
Cooling circuit

Coolant expansion tank

EGR EGR main Oil radiator

Radiator Cabin heating
Valve radiator

Bypass EGR pre-

radiator

Thermostat

Crank case output manifold

Cylinder 1-4 ; Cylinder head 1-4 EGR manifold

Crank case input manifold

Water pump pressure side

Coolant pump

Coolant pump intake

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1
1
Cooling circuit diagram 4H50 –
within the engine
Cooling circuit

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Crank case
output manifold

Air vent
cylinder head

Bypass thermostat
Crank case
Input manifold

Water pump pressure side

Water pump

Return expansion tank

Return coolant radiator

Water pump intake

 Cooling circuit diagram 4H50 –
Cooling circuit

radiator and cabin heating

Air vent
radiator

Intake from
crank case output manifold

Return pipe cabin heating

Input radiator

Supply from radiator

to water pump intake

Supply
cabin heating

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1
1
Cooling circuit diagram 4H50 – exhaust
gas recirculation and oil radiator
Cooling circuit

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EGR Valve
Return from EGR
EGR manifold to coolant manifold

EGR pre-cooler
Air vent
expansion tank

EGR main cooler

Coolant manifold

Intake EGR manifold

crankcase manifold Intake from EGR manifold
to oil radiator

Return from coolant manifold

to water pump Return from oil radiator
to coolant manifold

Oil radiator
Sealants and adhesives

Application of sealant and adhesive material:

502 230 01 Loctite Activator 500 ml

700 189 18 Loctite 243 50 ml
502 234 00 Loctite 648 10 ml
502 825 01 Silicon 30 ml
700 218 15 Silicon 300 ml
502 830 02 high-temperature paste 1000 g

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1
Special tools and workshop equipment

Assembly/disassembly cylinder head + exterior area

No. Ident no. Designation

1 626 383 00 Piston ring collet chuck ø 70 - 100mm

2 612 099 00 Multi-tooth wrench socket M8
3 620 307 01 Strap wrench
4 612 090 01 Piston ring expander
5 700 217 64 Socket wrench for cyl.K E14 1/2"
6 700 106 34 Socket wrench SW 27 for oil pressure sensor
7 700 106 76 Socket wrench SW 36 for oil filter adapter
8 653 368 00 Centering bolts for engine mount
9 653 474 00 Measurement device for gap
10 700 113 94 Hose clamping tongs
11 702 534 99 Kink torque wrench
12 702 534 97 Screwdriver torque
13 702 534 98 Rotation angle measurement device (Gedore)

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 1

10
8

11

13

12

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1
Special tools and workshop equipment

Assembly/disassembly - engine

No. Ident no. Designation

1 653 480 00 Counterholder for flywheel

2 653 466 00 Assembly pin for roller tappet
3 653 464 00 Magnet holder for roller tappet guide
4 653 517 00 Turning device for engine benches
5 702 517 89 Socket wrench for conrod T50 1/2"

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1 2

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1
Special tools and workshop equipment

Component servicing

No. Ident no. Designation

1 629 223 01 Valve lifting tool

2 634 142 00 Honing tools 50-175
3 634 143 00 Replacement stones for honing tools

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 1

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1
Special tools and workshop equipment

Test bench set-up

No. Ident no. Designation

1 -------- Part cannot be ordered individually, please order group

2 -------- Part cannot be ordered individually, please order group
3 652 948 00 Engine mountings F2F
4 647 639 00 Guard tube
5 629 242 00 Adapter for guard device
6 612 963 01 Base frame "large"
7 618 996 00 Machine bearing "replacement"
8 -------- Part cannot be ordered individually, please order group
9 -------- Part cannot be ordered individually, please order group
10 654 197 00 Engine mountings OPU

1 3 - 4H50 / 07.2015
 10 (8-9)
8

3 (1-2)

2
4

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1
Special tools and workshop equipment

Test bench set-up

No. Ident no. Designation

1 624 851 01 Temperature measurement device

2 624 861 01 Sensor extension cable
3 653 290 00 Assembly table
4 635 303 90 Adapter flange 6-8-hole
5 631 147 90 Driven flange
6 630 705 00 Drive shaft 8-hole
7 630 706 00 Rod end 8-hole "new"
8 634 287 00 Rod end 8-hole "replacement"
9 634 286 00 Joint insert 8-hole

1 3 - 4H50 / 07.2015
 3
1
2

˚C
4

7
5

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1
Special tools and workshop equipment

Adjustment and diagnostic equipment

No. Ident no. Designation

1 624 838 92 Revolution counter for fuel pressure pipe

2 --------- Part cannot be ordered individually, please order group
3 638 342 00 Charging cable with 12V pole clamps
4 --------- Part cannot be ordered individually, please order group
5 638 340 00 Cable for Piezo sensor
6 631 965 00 Piezo sensor 6mm
7 638 341 00 Photo sensor with cable
8 641 236 00 Speed differential adapter
9 639 123 00 Holder for photo sensor 1B
10 638 343 00 Speed sensor for ignition cable
11 635 776 00 Photo sensor with cable
12 634 268 00 Cable for Piezo sensor
13 702 503 97 Reflex marks (1 sheet = 35 pieces)

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 2 3

4
1 (2-7,13)

7 13

9 10

11 12

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1
Special tools and workshop equipment

Adjustment and diagnostic equipment

No. Ident no. Designation

1 --------- Part cannot be ordered individually, please order group

2 --------- Part cannot be ordered individually, please order group
3 --------- Diagnostic tool (Bosch) VCI
4 653 772 00 BG diagnostic tool VCI
5 702 536 30 Return flow quantities measurement device

1 3 - 4H50 / 07.2015
 1

2
VC
I

4 (1-3)

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1
Special tools and workshop equipment

Cooling system

No. Ident no. Designation

1 702 530 56 Radiator vacuum filling device

2 702 530 57 Tank for filling device

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1

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1
Special tools and workshop equipment

Electrical equipment

No. Ident no. Designation

1 700 318 32 Crimping pliers "Garant F28/95"

2 700 348 26 Mounting pliers "Deutsch HDT 48-00"

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1

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1
2. Additional equipment

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2
 Z 01 Main fuel filter

2
Absolute cleanliness!

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Protective caps may
only be removed from
the parts directly before
mounting!

Filter head

2 x washer 10.5

2 x cylinder screw
M 10x30
46 Nm

KRST main filter

2 x sealing ring A
16x22

Ring nipple

KRST line

Hollow screw 10-3

55±5 Nm
 Z 02 Suction hose
Hexagon nut M 6

2 x cylinder screw
M 6x12
9.5 Nm

Bracket

Cylinder screw
M 6x16
9.5 Nm

Pressure sensor

Sleeve

Adapter fittings

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2
 Z 03 Oxidation catalytic converter

2
4 x hexagon nut
VM 8
23 Nm

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Gasket

Oxidation catalytic
converter
2 x spacers
(incl. piping, flange
and support)
2 x washer 10.5

2 x cylinder screw
M 10x60
46 Nm

Fastening

2 x washer 10.5
2 x washer A 8.4
2 x cylinder screw
M 10x30
2 x hexagon bolt
Secure with
M 8x20
Loctite 243
Secure with Loctite 243
46 Nm
23 Nm
 Z 05 Alternator

Washer 8.4
Hexagon nut M 8
Cylinder screw
M 8x20
Washer B 8.4
23 Nm

Flange sleeve
Tensioning arm
Cylinder screw
M 8x35
23Nm
Alternator 14V/110A
Poly v belt
2 x spring pin 12x10
6PK 768
Pretensioning of new
Hexagon nut M 10
belt: 480 + 50 N
Pretensioning after
Washer 10.5
service: 250 + 30 N
Minimum pretensioning
Console
force: 170 N
3 x cylinder screw
M 10x35
Cylinder screw
46 Nm
M 10x130
46 Nm

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2
 Z 05 Starter

2
Starter bracket cover

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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
 Z 06 Engine base

3 x engine base

Cover plate with oil filler

15 x washer 10.5
and engine base
9 x cylinder screw
M 10x55
46 Nm

2 x cylinder screw
M 10x35
(in the crankcase)
46 Nm

O-ring Ø7x2 FPM

4 x cylinder screw
M 10x40
(in connection housing)
Apply Loctite 5910 to
46 Nm
sealing rope Ø1 mm

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2
 Z 07 Oil cooler

2
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Oil cooler_KTR

Double nipple
Secure with Loctite 648
40 Nm
Threaded pin M 8x10
Throw away filter
10 Nm
 Z 07 Oil cooler

Pipe clamp
Shaped hose piece
RSGU 1.25/15
8x3
fastened with
Washer 6.4
2 x hose clamp
DIN 3017-A 10-16x7.5
Hexagon bolt
1.5 Nm
M 6x16
9.5 Nm
Distributor

Shaped hose piece

fastened with
2 x hose clamp
Shaped hose piece
DIN 3017-A 12-22x9
16 x 4.5
3 Nm
fastened with
1 x hose clamp
2 x hose clamp
DIN 3017-A 16-27x12
DIN 3017-A 12-22x9
5 Nm
3 Nm
1 x hose clamp
DIN 3017-A 20-32x13
5 Nm

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2
 Z 30 Fan

2
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Exhaust fan
Spacer for fan

3 x spring washer A 6

3 x cylinder screw
M 6x35
9.5 Nm
3. Basic engine equipment

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3
 M 01 Cylinder crankcase

3
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Dipstick complete

Oil pressure sensor

DS-M1-TF
37.5 Nm

Check valve
Heed installation posi-
tion!
 2 x cylinder pin 6 m6x12 M 01 Cylinder crankcase
press in to specified dimension
4 mm
Secure tube connectors
with Loctite 648 and
press into cylinder block
up to the stop

Secure check valve

(Provent) with
Oil overpressure valve: Loctite 243
Piston for oil overpres- 12.5 ± 2.5 Nm
sure valve

Pressure spring

Sealing ring A 24x29

Screw plug
M 24x1.5
100 ± 10 Nm

2 x cylinder pin
14 m6x28
press in to specified
Secure check valve dimension
(oil pre-separator) with

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Loctite 243

3
12.5 ± 2.5 Nm
 M 01 Cylinder crankcase

3
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Piston cooling complete

Oil spray nozzle

Valve screw N8
27 ± 2 Nm
 M 02 Crankshaft
Insert main bearing Insert thrust washer with
halves into cylinder grease.
block main bearing Oil pockets point to the
bracket and moisten crankshaft sliding sur-
with engine oil. faces!

Heed the correct posi-

tion of the oil holes and
the position groove.

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3
 M 02 Crankshaft

3
3 - 4H50 / 07.2015
Thread crankshaft into
cylinder block.

Ensure axial play of

the crankshaft through
correct mounting of the
main bearing bracket
with thrust washers.

Before tightening the

screws on the main
bearing bracket, put
the crankshaft and the
main bearing bracket in
the specified direction
to the system.

Force transmission points as close

as possible to separating plane
 M 02 Crankshaft
3 1 5 7 9

Tighten main bearing

bracket in the specified
sequence.

Tightening torque:
1st level: 10 Nm
2nd level: 45 Nm
3rd level: 90 Nm

4 2 6 8 10

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3
 M 04 Camshaft

3
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Cylinder pin 8 x 50

Threaded pin M10 x 10

Mount with Loctite 243
Tighten threaded pin up
Grease camshaft bear- to stop
ing points with engine (max. 5 Nm),
oil and insert camshaft then loosen half to
into cylinder block. three-quarters of a turn.
 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.

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3
 M 01 Connector housing

3
3 - 4H50 / 07.2015
Apply sealing agent
Loctite 5910
according to the black WDRI 55x70x8
curve. Oil slightly and press in
until flush with flange
surface
 M 01 Connector housing
Place connector hous-
ing on cylinder block
and tighten slightly by
hand with the three
screws 1.
Screw special tool
onto cylinder block 2
(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 2
order to avoid distortion,
tighten all 19 combi
screws (23 Nm). 1
Tighten special tool
with screws 3 again
(camshaft / crankshaft
is blocked).
Special tool
19x combi screw 651 692 00
ISO 10644 (ISO 4017
+ 10673 N)
M 8x25 - 8.8 - A3B
23 Nm
3

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3
 M 17 Flywheel

3
Speed sensor
DG6-S for flywheel

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Cylinder screw M 6x20 8.8
Caution! 9.5 Nm
Remove speed sen-
sor before dismounting Sprocket
the flywheel and only Mount in correct position at
install after mounting approx. 250°C (beveled side
the flywheel; otherwise of the teeth must point in the
it can be damaged by direction of the starter)
the sprocket.
Keep soiling to a mini-
mum!
Front side is magnetic!
Avoid contact with iron
particles!

7x cylinder screw
M 10x1x80 12.9
95 Nm
 M 10 Oil pump

Rope seal
Grease slightly for
mounting
Cylinder screw
2x spring pin 8x8 M 5x10 8.8
5.5 Nm

Cover for oil pump

Bulkhead

Rotor set

WDRI 40x62x7

Grease slightly for

mounting and press in
flush with housing

8x cylinder screw

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M 6x20 8.8
9.5 Nm

3
 Z 30 Pulley

3
3 - 4H50 / 07.2015
Pulley crankshaft
ø103 PK6

Special tool Bevel to the crankshaft

651 692 00
Remove after tighten-
ing the pulley. Tension washer 16

Cylinder screw
M 16x1,5x40 LH
Left thread!
200 Nm
 M 05 Piston and conrod

Mount piston in cylinder

block with help of the
piston ring collet chuck
626 383 00 (heed notch
for oil spray nozzle).

Connect piston to con-

rod, position grooves of
the conrod bearing and
notch for the oil spray
nozzle on the piston are
on the same side!

Mount bearing seats in Tighten conrod screws.

conrod and oil (position 20 Nm + 65°
grooves are on the same
side)

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3
 M 10 Intake manifold

3
Intake manifold complete

2 x cylinder screw
Apply surface sealant

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M 8x16 8.8
Loctite 5910 here
Glued in with Loctite 243
23 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
M 6x13 8.8-A3D 1st screw connection
9.5 Nm (Ø6.2+0.1)
serves the positioning

Cu – sealing ring
Cu – sealing ring
Screw plug
AM 22x1.5 Magnet screw plug
50 Nm AM 22x1.5
50 Nm

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3
 M 36 Water pump

3
3 - 4H50 / 07.2015
2 x spring pin 8x8
first mount in crank-
shaft

Cylinder screw
M 6x20
9.5 Nm

11x cylinder screw

Phase encoder for
M 6x20
NW
9.5 Nm
 Place roller tappet on M 01 Roller tappet
special tool 653 466 00
and insert into crank-
case.

Marking for radial align-

ment

Special tool 653 464 00

Insert guide pins with

special tool 653 464 00
into crankcase.
Ensure with a slight
turning of the roller tap-
pet that the guide pin
is in the groove of the
roller tappet.

Threaded pin
M 10x10
Mount with Loctite 243

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5 Nm

3
 M 07 Cylinder head

3
Valve cone MK6

Plate spring

Valve spring inlet/outlet

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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.
 M 07 Cylinder head
Choosing the right cylinder head seal engine H50
ƵƐǁĂŚůLJůŝŶĚĞƌŬŽƉĨĚŝĐŚƚƵŶŐDŽƚŽƌ,ϱϬ
Gap 0.6...0.7
^ƉĂůƚŵĂƘϬ͕ϲ͘͘͘Ϭ͕ϳ
Ϭ͕ϴϱ
gap

projecting
measurement
Ϭ͕ϴ

Ϭ͕ϳϱ
piston

Ϭ͕ϳ

Ϭ͕ϲϱ
0,6 mm

Ϭ͕ϲ

Gap SM [mm]
^ƉĂůƚŵĂƘ^D΀ŵŵ΁
Ϭ͕ϱϱ
0,5 mm

Ϭ͕ϱ

Ϭ͕ϰϱ
0,4 mm

Ϭ͕ϰ
Ϭ͕ϯϱ Ϭ͕ϯϳ Ϭ͕ϯϵ Ϭ͕ϰϭ Ϭ͕ϰϯ Ϭ͕ϰϱ Ϭ͕ϰϳ Ϭ͕ϰϵ Ϭ͕ϱϭ Ϭ͕ϱϯ Ϭ͕ϱϱ Ϭ͕ϱϳ Ϭ͕ϱϵ Ϭ͕ϲϭ Ϭ͕ϲϯ Ϭ͕ϲϱ
projecting measurement of the piston Ü [mm] (average values from
<ŽůďĞŶƺďĞƌƐƚĂŶĚƐŵĂƘm΀ŵŵ΁;ŐĞŵŝƚƚĞůƚĂƵƐĂůůĞŶLJůŝŶĚĞƌŶͿ all cylinders)

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3
Determine piston protrusion with special tool 653 474 00 and select cylinder head seal according to table.
 M 07 Cylinder head

3
3 - 4H50 / 07.2015
13 11 12 14
Cylinder screw
M 6x80
Tightening process
Combi screw
11 - 14
M 12x130 8 4 2 6 10
9.5 Nm
Tightening process
1 - 10
1st stage: 20+2 Nm
2ndstage: 75°+5°
3rdstage: 75°+5°
greased with TA White!
7 5 1 3 9
 M 07 Rocker arm

Rocker arm bearing Rocker arm inlet com-

block plete
with axle

Rocker arm outlet com-

plete Locking ring A 18x1

Locking ring A 18x1

as needed
Adjusting ring
15x21x0.2
Adjusting ring

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15x21x0.3

3
Play: 0.1 ... 0.2 mm
 M 07 Rocker arm

3
Hexagon nut VM 8
23 Nm

Rocker arm bearing

block complete

3 - 4H50 / 07.2015
with levers

Basic setting tappet Push rod

clearance:
Turn the cylinder to be
adjusted in the working
cycle.
Loosen the lock nut and
turn adjusting screw in
until the calotte of the ad-
justing screw lies against
the spherical head of the
push rod.
From this position, turn
the adjusting screw 1 1/4
turns in and secure with
lock nut.
 M 08 Cylinder head cover
Hexagon bolt
M 6x20 -F- A3B
9.5 Nm Screw plug for oil filler
with RK ring 26x35x3
tighten hand-tight

Cylinder head cover

Paper seal for the

cylinder head cover

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3
 Z 05 Glow plugs

3
Hexagon nut M 4

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max. 2.5 Nm

Washer 4.3

Pencil glow plug

GLP 2 11V
apply high-temperature
paste
10 - 15 Nm
 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 silicone
Housing thermostat grease

Washer 6.4

Hexagon bolt
M 6x25

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3
 M 28 Exhaust manifold

3
Gasket

3 - 4H50 / 07.2015
(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 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 for the crimping
at will)

3 x hex nut VM8

23 Nm

Clamp Gasket

Hexagon bolt 2 x washer

M 6x16 A 6.4 DIN125
9.5 Nm
2 x hexagon bolt
Oil return line M 6x16
9.5 Nm
2 x sealing ring A 16x22

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Hollow screw 10-3

3
45 Nm
 M 30 Lifting device

3
3 - 4H50 / 07.2015
Lifting eye

2 x cylinder screw
M 8x20
23 Nm
 Note: M 37 Exhaust gas return
To guarantee a tension-
free assembly, the
mixing nozzle, the AGR
cooler and the housing
with bracket must first Gasket
be pre-mounted with-
out tightening and then Mixing nozzle
tightened in the speci-
fied sequence.

Lifting eye

Washer 10.5

2 x hexagon bolt
M 10x70 A3C

2 x cylinder screw
M 8x25 A3C
23 Nm

Console

Cylinder screw
M 8x20 A3C

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23 Nm

3
 M 37 Exhaust gas return

3
2 x gasket

AGR cooler
Heed installation posi- 2 x hexagon nut
tion (marking)! VM 8

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Housing

4 x cylinder screw
M 8x25 A3C Gasket

Bracket

4 x cylinder screw
M 8x20 A3C
 M 37 Exhaust gas return
Tightening sequence:

Position 1:
2 x hexagon nut
VM 8
23 Nm

Position 2:
3
2 x cylinder screw 1
M 8x25
23 Nm

Position 3:
2 x cylinder screw 2
M 8x25
23 Nm

Position 4:
2 x hexagon bolt 4
M 10x70
46 Nm

Position 5:
4 x cylinder screw
M 8x20 5
23 Nm

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3
 M 37 Exhaust gas return

3
4 x cylinder screw
M 5x12
5.5 Nm

Bar

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Shaped hose piece
16x4.5

AGR valve 2 x hose clamp

12x22x9
2 x hexagon bolt
M 6x16
9.5 Nm

O-ring 8x2

Shaped hose piece

22x4.5

2 x hose clamp
20x32x13
 M 37 Exhaust gas return

Hose clamp with wave

spring

Shaped hose piece

45 x 5

Hose clamp with wave

spring

Cylinder screw
M 5x16
5.5 Nm
Washer 5.3

Pressure-temp. sensor
DS-S3-TF for charge air

Sensor holder

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3
 M 14 Injection system

3
General instructions:
All work on the injection system may only be done in the voltage and pressure-free state (disconnect battery).
During all work on the injection system, cleanliness must be heeded in order to avoid the entry of particles into the injection system or the engine.
After every loosening of a pressure tube, it must be replaced!

Mounting of injectors on the engine

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Remove the protective caps only right before mounting. Make sure that the nozzle cap and thus the injection holes are not damaged. Moisten ex-
terior gaskets (O-rings) with installation oil, engine oil or diesel. Lubricants and glide agents that contain water are not permissible.
Before mounting, it may be necessary to check the correct position of the copper sealing disk on the nozzle clamping nut.
Attention must be paid that the injector is inserted into the cylinder head bore without damage. A transmission of force to the return connection or
the plastic overmold must be avoided.
All plug connectors must be snapped in securely and locked during mounting.
The cap nut of the high-pressure line must be 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 intended operation.
The injector does not have to be ventilated before initial start-up.

Dismounting of injectors on the engine

The dismounting of the injectors must be done analogously to the mounting. Open connections must be sealed with protective caps.
To loosen the high-pressure screw connection, hold the hexagon of the inlet connector tight. With a loosened inlet connector, the high-pressure
seal of the injector is no longer guaranteed.

Remounting of injectors on the engine

After each loosening of an injector, the old copper sealing ring must be removed and a new one used.
In order to get cylinder-specific correction data for the engine controller, the injectors should be inserted on the original cylinder when re-using. In
principle, the installation on other cylinders is also possible, however only if the IMA correction values are read into the control unit again.
Injectors can be cleaned before re-installation below the high-pressure connection in vertical position in the ultrasound bath.
Mechanical cleaning of the nozzle shaft with brushes is impermissible in order to prevent damage to the injection holes.
 M 14 Injection system
Fuel return line:
max. number of plug assembly/removal (plugging in; locking; unlocking; removing the plug from the counter piece): 10x
If during the removal of the plug connectors the O-ring on them is damaged, then the entire return line must be replaced.
Before re-mounting of the plug connectors, it must be ensured that the counter pieces are not soiled or corroded.
Hose-nozzle connections may not be loosened. The mounting of the fuel return line on the vehicle low-pressure circuit and on the injector must be
done dry (without mounting 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).
Then close the locking bar (bar must snap into the closed position and be even with mounting surfaces)(picture 2).
In order to guarantee the function, the return plugs must be mounted according to the mounting instructions above.
Otherwise fuel can escape!

Dismounting:
Dismounting must be done by hand.
Open safety bar. Meanwhile, press on mounting surface in plug direction (safety bar must snap into open position (picture 3). Then remove return
plug from injector return connection (picture 4).

Safety bar

Contact surface
Mounting surfaces
Picture 1 picture 2 picture 3 picture 4

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3
 M 14 Injection system

3
Before the installation or View A
removal of the high-pres-
sure pump, the crank-
shaft must be turned
into the position "CP4"
(marking visible through

3 - 4H50 / 07.2015
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
high-pressure pump.
Mounting precision:
± 1 tooth.
For mounting, grease the
O-ring slightly (silicone Marking gear wheel CP4
grease)

View A
 M 14 Injection system

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

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3
 M 14 Injection system

3
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2 x cylinder screw
Fuel line M 8x20
23 Nm
Washer 8.1x20x3

Hexagon nut
M8

Lug High-pressure rail

Fuel pressure tube
10 Nm + 60°(rail side)
15 Nm + 60°(pump 2 x hexagon bolt with
side) flange
M 8x30
23 Nm
 M 14 Injection system

Fuel return line

Fuel pressure tube
Cylinder 3+4
10 Nm + 60° CR injector

Hexagon nut M 8
23 Nm
Fuel pressure tube Bushing for injector
Cylinder 1+2
10 Nm + 60° Clamping claw

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3
 M 31 Crankcase ventilation

3
3 - 4H50 / 07.2015
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
4. Tables

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4
4 3 - 4H50 / 05.2016
Screw tightening torque

General [Nm]:

Nm  9.81(10) = kpm
Nm  1.3558 = Lbs ft

Screw quality
Thread
5.8 8.8 10.9 12.9

M 4 1.7 2.8 3.9 4.7

M 5 3.4 5.5 7.8 9.3

M 6 6.0 9.5 13 16

M 8 14 23 33 39

M 10 29 46 65 78

M 12 50 80 110 140

M 14 80 130 180 220

M 16 120 190 270 330

M 18 170 270 380 450

M 20 240 380 530 640

M 22 320 510 720 860

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4
Screw tightening torque

4 3 - 4H50 / 05.2016
Screw tightening torque

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4
Identification on wiring diagrams (DIN 40719)

Identifier Designation of the electrical components

A1 Instrument box
A2 Instrument plate
A3 Start stop automatic
A4 Starter protection module
B1 Temperature sensor
B2 Speed encoder
B3 Oil pressure sensor
B4 Signal horn
C1 Condenser
E1 Heater for fuel filter
F1 Fuse
G1 Battery
G2 Three phase alternator
G3 Flywheel alternator
H1 Indicator light for alternator control
H2 Indicator light for oil pressure
H3 Indicator light for engine temperature
H4 Indicator light for air filter (maintenance switch)
H5 Indicator light for belt break
H6 Indicator glow monitoring
H7 Indicator light fan monitoring
H8 Remote display: engine on
K1 Control relay 1 for start / restart block
K2 Control relay 2 for pre-glow
K3 Control relay 3 for speed adjustment
K4 Engine protection relay
K5 Delay relay
K6 Start block relay
K7 Time relay (impulse relay)
K8 Power relay
M1 Starter motor
MG Starter alternator
N1 Controller for starter alternator
N2 Controller for flywheel alternator
N3 Controller for three phase alternator (if not integrated)
N4 Impulse encoder (additional for synchro)controller

4 3 - 4H50 / 05.2016
Identification on wiring diagrams (DIN 40719)

Identifier Designation of the electrical components

P1 Operating hours counter

P2 Tachometer
P3 Pressure indicator
R1 Glow plug
R2 Heating flange
R3 Series resistor for glow system
R4 Resistor
R5 Series resistor with thermo time switch
S1 Glow start switch (5 - digit)
S2 Main switch
S3 Glow plug starter switch (3 - digit)
S4 Start stop switch
S5 Switch for speed adjustment
S6 Temperature switch for engine temperature
S7 Oil pressure switch
S8 Pressure switch for air filter
S9 Fan monitoring switch
S 10 Temperature switch for pre-glowing
S 11 Remote start switch
S 12 Remote stop switch
T1 Transmitter for speed measurement
V1 Uncoupling diode
V2 Free-wheel diode
V3 Zener diode
V4 Suppressor diode
W1 Mass, minus return line
W2 Screened line on the alternator
X1 Terminal block on the instrument box
X2 Flat power strip
X3 Plug on emergency stop switch
X4 Outlet on emergency stop switch
X5 Terminal block in the operator box / terminal box
Y1 Lift magnet for speed adjustment
Y2 Lift magnet for engine switch-off
Y3 Servo magnet (=valve magnet) for engine switch-off
Y4 Fuel shut-off valve
Y5 High pressure reset valve
Z1 Suppression choke
Z2 Suppressor capacitor

3 - 4H50 / 05.2016
4
HATZ cable marking

Terminal Designation
0 Ground
1 Alternator B+
2 For three phase alternator: D+
for flywheel alternator: terminal L on the controller
3 Starter terminal 50
4 Oil pressure switch
5 Temperature switch on the cylinder head
6 Glow plug I
7 Electromagnet for engine switch-off
8 Glow plug II
9 Start stop input
10 Plus terminal for direct current motor speed fine adjustment
11 Minus terminal for direct current motor speed 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 Maintenance switch for air filter
18 Electromagnet for engine switch-off (pick-up winding)
19 Temperature sensor on the cylinder head
20 Oil temperature switch
21 Fan monitoring switch
22 Terminal W for speed measurement
23 Starter 30 (for ammeter connection)
24 Terminal C for controller on flywheel alternator
25 Oil temperature sensor
26 Terminal 50f on the starter protection module
27 * * * Reserved * * *
28 Speed adjustment magnet (pick-up winding)
29 * * * Reserved * * *

4 3 - 4H50 / 05.2016
Bosch designation for cable marking

Bosch Hatz German designation English designation

INJ11 M1 INJektor Bank 1 - Zylinder 1 (1. Zylinder) INJector bench 1 - cylinder 1 (1. cylinder)
INJ12 M2 INJektor Bank 1 - Zylinder 2 (4. Zylinder) INJector bench 1 - cylinder 2 (4. cylinder)
INJ21 M3 INJektor Bank 2 - Zylinder 1 (3. Zylinder) INJector bench 2 - cylinder 1 (3. cylinder)
INJ22 M4 INJektor Bank 2 - Zylinder 2 (2. Zylinder) INJector bench 2 - cylinder 2 (2. cylinder)
FLPS1 B4 Kraftstoff Niederdruck u. Temp. Sensor Fuel Low Pressure and temp. Sensor
OPS B3 Öldruck/Temperatur Sensor Oil Pressure/ Temperature Sensor
MEU K2 Hochdruckpumpe mit Zumesseinheit High Pressure Pump with MEtering Unit
RDS B1 Rail-Druck Sensor Rail-Pressure-Sensor
DRV K1 Druck-Regel-Ventil Pressure Control Valve
CAS B7 Nockenwellen-Drehzahl Sensor CAmshaft Speed Sensor
BPS B2 Ladedruck-/Temperatur Sensor Boost Pressure-/ Temperature Sensor
CTS B5 Kühlmittel-Temperatur Sensor Coolant-Temperature Sensor
CRS B6 Kurbelwellen-Drehzahl Sensor CRankshaft Speed Sensor
ATS B8 Ansaugluft-Temperatur Sensor Air Temperature Sensor
WFS B9 Wasser im Kraftstoff Sensor Water in Fuel Sensor
CLS S7 Kühlmittel-Niveau Sensor Coolant-Level Sensor
AFDPS B10 Luftfilter-Wartungs Sensor Air Filter Difference Pressure Sensor
EGRPS B11 AGR-Druck Sensor EGR-Pressure Sensor
EGR M7 Abgas-Rückführ Ventil Exhaust-Gas-Recirculation Valve
EDC Elektronische Dieselregelung Electronic Diesel Control
EKP Elektro-Kraftstoff-Pumpe Elektric-Fuel-Pump
EMV ElektroMagnetische Verträglichkeit Electromagnetic Compatibility
EPW Elektro-Pneumatischer Wandler Electro Pneumatic Converter
HFM Heißfilm-Luftmassenmesser Hot Film Air Mass Sensor
HS High-Side
LS Low-Side
LDF Lade Druck Fühler Boost Pressure Sensor
NTC Negativer Temperaturkoeffizient Negative Temperature Coefficient
OBD OnBoard-Diagnose On Board Diagnostic
OL Open Load
PTC Positiver Temperaturkoeffizient Positive Temperature Coefficient
PWG Pedal Wert Geber Accelerator Pedal Sensor
APP Pedalposition Accelerator Pedal Position
SG SteuerGerät Control Unit
ECU SteuerGerät Electronic Control Unit
VTG Lader mit variabler Turbinengeometrie Variable Turbine Geometry
ZME Zu-Mess-Einheit Metering Unit

3 - 4H50 / 05.2016
4
4
F
EG FDP
O R S-
AF LS - PS - Fue
C DP Oi EG l fi
BA LS - S - l leve R P lter d
T- Co Air l 3 if
-B ola filt sen diffe feren
AT a n e s

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S- t ter t r d o r r e nti tial p
Air ie level iffer al
M e pre ress
tem inu sen
s
nti
a ss u
WF s
Cable harness max.

pe or lp
S- rat s wit r e s
ure re se
se n
Wa ure ch sure ns sor s
ter se se o r ign
in ns
or ns al
fue
l le o r
ve
ls
en
so
r

S
Sta TRT
rt r L/P
AP ela SP
P- y/ R
Ac ele LY1
ce ctr
GC ler ic
fue
U ato
rp lp
-G um
low e da pr
CA c o l ela
N1 ntr y1
-C ol
un
BA AN
-B i t
T+ us
-- -B 1 ,F
- att
eri las
eP hp
lus rog
VS ram
FH S - mi
R R L V eh ng
GN MTA Y - icle ,C
AC SW PP F ue sp
CP
S - l e ,D
CR
C W -G Re filte ed iag
FT - e m r s e no
sti
FL LSW - Cru AC r ar ne ote A heat nso
C e e r cs
IM qu utra cc r re
FT P H
NS 1 - ise
- F c o e s l s e l e l a
E LS - In Ful u e nt t sw witc ato r y
tak e c l tan rol itc rp
CO NGN W2
- e o n k l h h ed
K6 NV -E Fu ma su ev al
CT 8 - el nif mp el s
- C ngi
BR LP RH2 lutc ne s ank t o ld tio en
F KM - C 2 h pe lev pre n ou sor
BR TLLP N - oola Swit switc ed o el s heat tput 1
BR KR - M nt ch h utp ens in s
KP ED War ain b tem ed b ut or g se ignal
S- - R nin rea per atte 2 ns
Pa e g k a r or
sw
rtk dund LED swit ture y UB
d itc
ing an for ch isp 2( h
bre t br em lay Hig
ak ea p h sid
sw k sw ty ta ed
itc itc nk
h h riv
er)
 Cable harness min.

EG
AF RP
CL D PS
S-
EG
BA S- -A R
T- C oo i r filt P3
er dif
ST
RT A TS
-B
att
lan
t le dif fer
e ve f er
en
tia
L/P -A rie ls e lp
AP SP ir t
e Mi
n e n
nti
a l res
P- RL WF mp u s s o pr su
Ac Y1 e r r s e s re
ce -S
S-
W a t u w i t s u
GC ler t a a re c h r es se
ns
U ato rt r ter se en or
-G rp ela in ns
o s o
low ed y / f ue r r
CA al ele l le
N1 co ctr ve
ntr ic ls
-C ol
u f ue en
so
BA AN nit lp r
T+ - Bu u mp
-B s1
,F r ela
-- att y1
- eri
eP
las
hp
lus rog
ram
mi
ng
,C
CP
,D
iag
no
sti
cs

3 - 4H50 / 05.2016
4
4 3 - 4H50 / 05.2016
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4
4 3 - 4H50 / 05.2016
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4
4 3 - 4H50 / 05.2016
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4
4 3 - 4H50 / 05.2016
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4
4 3 - 4H50 / 05.2016
3 - 4H50 / 05.2016
4
4
CAN speed adjustment H50

Hand lever Gas pedal Gas rotary knob

3 - 4H50 / 05.2016
sensor output signal

Pin No. Pin assignment Pin

1 Supply B - cc
2 Supply B + dd speed adjustment
3 CAN high aa position [°]
Connection 4 CAN low bb
CAN speed adjustment 5 shield - Lower upper
6 not assigned - idling speed idle speed

motor connector
Customer control unit

custom cabling

10.2015
VMM-AH
 Analog speed adjustment H50

Hand lever Gas pedal Gas rotary knob

Pin No. Pin assignment Farbe Pin

1 Voltage supply +5 V Rot A
Signal 1 2 Ground Blau C
4 Signal 0,5 V – 4,5 V Braun B
6 Voltage supply +5 V Orange D sensor
Signal 2 5 Ground Schwarz F output signal
3 Signal 0,25 V – 2,5 V Grün E
voltage

speed adjustment
position [°]
harness connector

3 - 4H50 / 05.2016
03.2015

4
VMS-MS
4 3 - 4H50 / 05.2016
3 - 4H50 / 05.2016
4
Cable routing DPF

4 3 - 4H50 / 05.2016
Cable routing

3 - 4H50 / 05.2016
4
Cable routing

4 3 - 4H50 / 05.2016
Cable routing

3 - 4H50 / 05.2016
4
Cable routing

4 3 - 4H50 / 05.2016
Cable routing

3 - 4H50 / 05.2016
4
Cable routing

4 3 - 4H50 / 05.2016
Cable routing

3 - 4H50 / 05.2016
4
Cable routing

4 3 - 4H50 / 05.2016
Cable routing

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4
Cable routing

4 3 - 4H50 / 05.2016
Cable routing

3 - 4H50 / 05.2016
4
Cable routing

4 3 - 4H50 / 05.2016
 Blink code
SHORT - LONG
1.1 Error source: Error in the monitoring, display and control elements area
Indicators or cabling ĚĞĨĞĐƟǀĞ͖
Possible error: power supply from control unit ŝŶƐƵĸĐŝĞŶƚ
other error, not ƐƉĞĐŝĮĞĚ in more detail
Check ĨƵŶĐƟŽŶ and cabling of the ŝŶĚŝĐĂƚŽƌƐ͖
Remedies: check power supply to the control ƵŶŝƚ͖
otherwise HATZ ^ĞƌǀŝĐĞ must perform ƚƌŽƵďůĞƐŚŽŽƟŶŐ

1.2 Error source: Error in the speed sensor area

Possible error: Crankshaft or ĐĂŵƐŚĂŌ sensor cabling faulty
Remedies: Check cabling

1.3 Error source: Error in the air supply area

Air ĮůƚĞƌ soiled
Possible error: charge air ĂŌĞƌ charge air cooler impermissibly high
cabling charge air sensor, intake underpressure sensor faulty
^ĞƌǀŝĐĞ air ĮůƚĞƌ
Remedies: clean charge air cooler
check cabling

1.4 Error source: Error in the exhaust return area

Cabling AGR sensor faulty
Possible error:
AGR ĐŽŽůĞƌͬǀĂůǀĞ clogged with deposits
Check cabling
Remedies:
Clean AGR ĐŽŽůĞƌͬǀĂůǀĞ

2.1 Error source: Error in the fuel low pressure system area
Water in ĨƵĞů͖
fuel pressure too low
Possible error:
fuel temperature too ŚŝŐŚ͖
cabling ĐŽŶǀĞLJŽƌ pump or sensor faulty
Drain water at fuel pre-ĮůƚĞƌ͖
check tank contents, Įůů͖ or replace clogged fuel ĮůƚĞƌ͖
Remedies:
ensure ƐƵĸĐŝĞŶƚ cooling of the ĨƵĞů͖
check cabling

2.2 Error source: Error in the fuel high pressure system area
Cabling of the sensor system (injectors, rail pressure sensor, pressure control ǀĂůǀĞ͕
Possible error:
high pressure pump) faulty.
Remedies: Check cabling

2.3 Error source: Error in oil temperature pressure area

Oil pressure too high/low
Possible error: oil temperature impermissibly high
sensor cabling faulty
Check oil ůĞǀĞů͕ if necessary ƌĞĮůů oil
use oil with appropriate ǀŝƐĐŽƐŝƚLJ class
Remedies:
check water hose oil cooler. (hose kinked) +possibly clean radiator
check ĐĂďůŝŶŐ͖

3.1 Error source: Error in the ŇƵŝĚ cooling area

Coolant ůĞǀĞů impermissibly low
coolant temperature impermissibly ŚŝŐŚ͖
Possible error:
cabling, coolant temperature sensor ĨĂƵůƚLJ͖
Sensor faulty
ZĞĮůů coolant
clean ƌĂĚŝĂƚŽƌ͖
Remedies:
check ĐĂďůŝŶŐ͖
replace sensor

3.2 Error source: Error in the pre glow system area

Cabling of the glow plugs ĨĂƵůƚLJ͖
Possible error: one or ƐĞǀĞƌĂů glow plugs faulty
glow plug control unit "GCU" faulty.
Check cabling
Remedies:
check ĨƵŶĐƟŽŶ of the glow ƉůƵŐƐ͖

3 - 4H50 / 05.2016
4
 Charge current curve 12 V

Charge current [A]

Engine speed [rpm]

Ambient temperature 25°C

Ambient temperature 80°C

4 3 - 4H50 / 05.2016
 Charge current curve 24 V

Charge current [A]

Engine speed [rpm]

Ambient temperature 25°C

Ambient temperature 80°C

3 - 4H50 / 05.2016
4